Free PDF Manual Guide

How to determine what type of brake calipers and ABS sytem is fitted. During development of the cruise control for the R1150GS we have been aware that there are two different types of front brake caliper and two different ABS systems fitted to this model, and some bikes without ABS. In order to supply the correct kit for the bike, we need to know what type of front brake calipers your bike has, and what ABS system (if any) the bike has. This is easy to determine by following the instructions below. Identifying the front brake calipers. The earlier models were fitted with Brembo brake calipers.
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This “how to” assumes you have some basic tools, and safety gear. Safety glasses should be worn at all times when working with tools and automotive fluids. Always use a hydraulic jack and safety stands when lifting or getting under a vehicle. If you are unsure on where to safety lift your vehicle, refer to its owners guide. Brake dust can contain asbestos which has been found to cause cancer. The writer of this how to assumes zero liability in how to use this guide, or any damages that may come from it to you, your property, or others and others property. If you are uncertain at any point, refer to a qualified automotive technician.
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Quick and to the point, the reason to change your brake fluid is to save your ass! Brake fluid is a hydroscopic which means it attracts water, big deal right? Wrong, through the brake lines and through your resevoir brake fluid attracts water, water has a really low boiling point, the more water in your lines the lower your boiling point. So you smash the brake pedal to stop you from slaming into the car ahead of you but your brakes barely keep you from hitting him. Your pedal feel may be very “mushy” as some may say. Your pads and rotors are fine so what’s the deal. When you slammed your brakes their is a good chance your brake fluid boiled, in turn becoming a gas. Which we all know you can compress gas a lot! So your pedal sinks to the floor. Of course that is worst case scenerio but that is the situation that we are trying to avoid by changing our fluid. Another reason is with our expensive ABS ESP etc. etc. we want to prolong their life as long as we possibly can, new brake fluid will keep corrosion to an absolute minimum.
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Following the steps for this Audi A4 Brake Installation Manual
PREPARATION FOR INSTALLATION
1. Be sure that the vehicle is parked on level concrete and the parking brake is on.
2. Place stops in front of and behind rear tires.
3. Consult owner’s manual for proper lifting and wheel removal procedures before lifting front of vehicle.
4. Place jack stands under vehicle for added stability.
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Everything is included in this kit to add a rear disc brake to your BBR Perimeter Aluminum Frame kit based motorcycle. If you are adapting this kit to the OEM Honda frame or another aftermarket frame kit, you will need our adapter kit PN 550-HXR-5050. Because installation of this kit is beyond the control of BBR Motorsports, Inc, we cannot accept responsibilty for misuse or improper installation. This kit is intended only for use on off-road motorcycles. These instructions are intended only as a supliment to the proper Honda service manual. If the installation of this product is beyond your technical abilities please refer to qualified service personel.

1. Support bike on stand with rear tire off of ground. Remove seat and body work. Remove rear wheel and brake pedal.
2. Remove shipping bracket from master cylinder.
3. Remove shipping wedge from the caliper.
4. Install master cylinder on frame using supplied 6mm bolts.
5. Install master cylinder reservoir on upper subframe bolt using the supplied bracket and longer bolt.
6. Slide caliper (on mount) onto back of swingarm
7. Stick brake hose mounts onto swingarm. Be sure to clean the swingarm to insure that they stick properly.
8. Install rotor and sprocket on the rear hub. BBR recommends using a thread lock adhesive on all these bolts
9. Install rear wheel. Use care to insure that the rotor slides between the brake pads and the wheel spacers stay in place.
10. Install brake pedal tip in desired location. BBR recommends using a thread lock here also.
11. Unsnap the clevis pin from the bottom of the brake reservoir.
12. Install the brake pedal spring on the top bolt mount.

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Most 17” wheels will clear the outer diameter of the caliper. Wheel weights mounted on the inside of the wheel may need to be repositioned. The more critical clearance is the spokes of the wheel to the outer face of the caliper. Do not assume an 18, 19 or even 20 inch wheel will clear the outer face of the caliper. A minimum distance of 60.81mm, measured from the outer rotor face to the inside face of the wheel spokes. This is the net metal-to-metal measurement. We recommend at least 2mm additional clearance to clear the ST-40 caliper on our big brake kits. Please refer to the Wheel Fitment section of our website to confirm any wheel fitment issues.
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Part Content:
This will also space out the entire wheel, widening the track width of the vehicle. Fender clearances should be checked on lowered cars, and longer lug studs or wheel bolts are usually required. Note: The Wheel Industry Council has issued guidelines advising wheel spacers not be used. It is the responsibility of the customer to insure wheel spacers are properly specified and installed.
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The procedure below was written up for a 1998 2.0 Twinspark with vented front discs but should be the same for all 156 models. The shape of the pads will differ between vented and solid discs at the front. Later models have larger rear discs and therefore different pads. It should not matter if we are talking standard brakes with normal or drilled/grooved discs with high-speed road pads – the process is the same. The only difference is that some front pads don’t have the wear indicator so you will need to tie the cable back out of the way if not required.
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This document is based upon an “ALFA Romeo Association Tech Session / Presented by Larry Dickman Jr., ALFA Parts Exchange” paper. Mike Nakamura used Larry’s guide to upgrade a 1971 Montreal and I used the information provided by Mike to upgrade my 1972 Montreal. I have added to the information provided by Mike to provide a little more clarification and detail.

Larry developed this upgrade to fit within common 14″ ALFA wheels and there are several routes one can follow to achieve the finished result. You can modify old 115 rotors creating iron hats and attach new rotors or you can have custom aluminum hats machined. The drawings provided are for custom hats. I have made every effort to insure that the information included is correct and I have successfully performed this modification to my own Montreal. If you find any errors and/or omissions you can contact me at alfagene@adelphis.net.
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Slip indicator light and Vehicle dynamic control VDC off indicator light in the Instruments and controls section Indicator light If malfunction occurs in the system and indicator lights come the on in the instrument panel As long as these indicator lights are on the traction control function is canceled. The Slip indicator will flash if wheel spin is detected The ABS will still operate with the VDC system off.

When the VDC system is operating you may feel a pulsation in the brake pedal and hear a noise or vibration from under the hood This is normal and indicates that the VDC system is working properly The computer has a built in diagnostic feature that tests the system each time you start the engine and move the vehicle forward or in reverse at a slow speed When the self test occurs you may hear a clunk noise and or feel a pulsation in the brake pedal This is normal and is not an indication of a malfunction WARNING The vehicle dynamic control system is designed to help improve driving stability but does not prevent accidents due to abrupt steering operation at high speeds or by careless or dangerous driving techniques Reduce vehicle speed and be especially careful when driving and cornering on slippery surfaces and always drive carefully Starting and driving 5 21 REVIEW COPY 2006 Quest van Owners Manual USA English nna 05 27 05 tbrooks REAR SONAR SYSTEM if so equipped If brake related parts such as brake pads rotors and calipers are not standard equipment or are extremely deteriorated the vehicle dynamic control system may not operate properly and the vehicle dynamic control off indicator light may come on Do not modify the vehicle s suspension If suspension parts such as shock absorbers struts springs stabilizer bars and bushings are not NISSAN approved for your vehicle or are extremely deteriorated the vehicle dynamic control system may not operate properly This could adversely affect vehicle handling performance and the VDC OFF indicator light may come on When driving on extremely inclined surfaces such as higher banked corners the vehicle dynamic control system may not operate properly and the VDC OFF indicator light may come on Do not drive on these types of roads When driving on an unstable surface such as a turntable ferry elevator or ramp the vehicle dynamic control off indicator light may illuminate

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