NED’s HYDRAULIC CLUTCH KIT

PARTS LIST / INSTRUCTIONS

Information collected and compiled by: Peter Goertz (Crazy Cunuc)

Prefix The intent of this document is ONLY meant to be a collaboration of ideas all in one place as a starting

guide for anyone looking to do the conversion. All of the information used in this document was

collected from various members from “Kawasaki Triples Canada” and I do not take credit for any of

the ideas shared.

THIS IS NOT AN OFFICIAL INSTRUCTION!!

ALL OF THE FITTINGS ARE REFERENCED FROM RUSSELL PERFORMANCE PRODUCTS ... LINKS INCLUDED IN DOCUMENT www.russellperformance.com

1.0 PARTS LIST SLAVE CYLINDER NED’s (Dave) Hydraulic Clutch Kit

- Hose Fitting Thread Pitch: 10 X 1.25mm - Piston Travel (With Magura 9.5mm M/C): 0.080” - Seal: 7/8” Wheel Cylinder Cup Seal

NAPA - PT# 3023 LINK: https://www.napaonline.com/en/p/UBP20412

MASTER CYLINDER Magura: OEM Replacement Master Cylinder 9.5mm – PT# 2000302

- Hose fitting Thread Pitch: 10 x 1.0mm - Magura Mirror Mount Bracket - PT# 2700177

*BOTH AVAILABLE ON EBAY https://www.amazon.com/dp/B000GV2920?tag=viglink20248-20

FLUID

- Recommended: DOT 5 Silicone Fluid NOTE: - Magura Master Cylinder seals are NOT compatible with Glycol Based Fluid.

- Since the Slave Cylinder cup seal is made for brake use it MAY NOT be compatible with Magura’s Mineral Oil “Blood” and expand the rubber.

SEALS - 10mm Parker Stat-o-Seals

*Available on Ebay

HOSE This is using all Russell Performance Parts. *This is only made as a quick reference guide for the Hose *Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc etc www.russellperformance.com RUSSELL Factory Assembled Universal Brake Hoses *Available in multiple finishes

- Available in a variety of lengths (Check on your bike before ordering) LINK: http://www.russellperformance.com/powersports/mc/brake-clutch-hose-kits/universal.shtml

FITTINGS *Available in multiple finishes This is using all Russell Performance Parts. *This is only made as a quick reference guide for the fittings

*Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc etc www.russellperformance.com

SLAVE CYLINDER Fittings

- Banjo Bolt 10mm x 1.25: PT# R40516C (Chrome Finish) - Banjo 45°: PT# R4055C (Chrome Finish) OR - Banjo 35°: PT# R4050C (Chrome Finish)

LINK: http://www.russellperformance.com/powersports/mc/adapter-fittings/index.shtml MASTER CYLINDER Fittings

*M/C to HOSE Thread Pitch 10mm x 1.0 - There have been TWO suggested methods (1) DIRECT HOSE TO M/C CONNECTION

- Male Flare Union: PT# R41431

(2) BANJO APPLICATION - Banjo Bolt 10mm x 1.0: PT# R40506 (Chrome Finish) - Banjo 45°: PT# R4055C (Chrome Finish) OR - Banjo 35°: PT# R4050C (Chrome Finish)

LINK: http://www.russellperformance.com/powersports/mc/adapter-fittings/index.shtml

2.0 INSTALLATION 2.1 SLAVE CYLINDER This is NOT meant as an “OFFICIAL” instruction but rather only a collaboration of tips/tricks from the various comments/members on the KTC forum.

Piston should be greased upon assembly as there is no fluid contact to lubricate this in service.

- Recommend very thick Silicone grease (compatible with rubber).

Ex. Dow Corning 111. Labeled "Valve lubricant and Sealant"

(for disk brake slider/pad tip lubrication). It does not wash off like other

caliper greases.

Ensure that Seal AND Piston are both orientated properly.

2.2 CLEARANCE / INTERFERENCE SLAVE TO ENGINE CASES

When installing the slave, be sure that it seats properly. Some applications may have slight interference. It can be resolved quickly with a dermal. Luckily, it's between the mounting bolts so it's easy to feel the rocking (the shiny spot on the top where there is a ledge from machining).

PERFECT FIT

PUSH ROD

IF you are using a ball bearing pusher you may be required to trim down your push rod accordingly to make up for the added length from the ball bearing pusher. *BE CAUTIOUS AND ENSURE THAT ALL MEASUREMENTS ARE CORRECT BEFORE TRIMMING

ENGINE COVER Based on your selected fitting application modification may be required to your LH Engine Sprocket Cover to accommodate the hydraulic clutch hose. *BE CAUTIOUS AND ENSURE THAT ALL MEASUREMENTS ARE CORRECT BEFORE CUTTING

2.3 MASTER CYLINDER / MIRROR MOUNT

2.4 FITTINGS

Applications vary based on Bike Model, Handle bars, Gauges, Carbs etc.

Refer to “1.0 PARTS LIST” for all LINKS to RUSSELL PERFORMANCE PRODUCTS SLAVE CYLINDER RECOMENDATIONS

- Banjo Bolt 10mm x 1.25: PT# R40516C (Chrome Finish) - Banjo 45°: PT# R4055C (Chrome Finish) OR - Banjo 35°: PT# R4050C (Chrome Finish)

MASTER CYLINDER RECOMMENDATIONS

*M/C to HOSE Thread Pitch 10mm x 1.0 (1) DIRECT - HOSE TO M/C CONNECTION

- Male Flare Union: PT# R41431

(2) BANJO APPLICATION

Available Russell Banjo bolt is too long. If it is cut the chrome plating may have a burr

and give troubles. *USE AT YOUR OWN RISK OR SOURCE A SHORTER BOLT - Banjo Bolt 10mm x 1.0: PT# R40506 (Chrome Finish) - Banjo 45°: PT# R4055C (Chrome Finish) OR - Banjo 35°: PT# R4050C (Chrome Finish)

2.5 HOSE RUSSELL Factory Assembled Universal Brake Hoses *Available in multiple Lengths & Finishes

The Russell hose length is quoted tip to tip and there is no compensation for the

additional length of the fittings.

DETRMINING HOSE LENGTH

Install the Master and Slave Cylinders with their respective fittings.

Using a piece of 3/8” ID fuel hose; route and trim as needed with the hose plugged onto

the threaded fittings.

Remove the fuel hose and measure its final length.

Use this value to determine the length of hose to order from Russell.

2.6 FINAL ASSEMBLY AND BLEEDING

*Refer to 1.0 Parts List; “Fluid”, for correct recommendations.

NOT ALL SEALS ARE COMPATIBLE WITH CERTAIN FLUIDS

Assemble and install your Master Cylinder and fittings / hose.

Leave the Slave Cylinder UNBOLTED from the Engine Cases.

DO NOT bleed through the Slave Cylinder’s bleed screw. Rather use it to fill the system

via a syringe.

Insure the line into the Master is LOWER than the ball end of the lever.

Make sure there are no high spots in the line

Hold the Slave Cylinder in one hand with a finger over the piston.

Pump the Master Cylinder so the piston comes out of the Slave Cylinder 0.125"

Slowly push the piston back into the bore.

*DO NOT push it all the way in; Seal damage CAN occur from being pushed past

the ports!

The DOT 5 fluid likes to froth.

GO SLOWLY!

Repeat until all the air is out.