Free PDF Manual Guide

Installation Procedure:
- Open trunk hatch, and pull off cover for the strut tower bolts.
- Remove the 14mm OEM nuts (requires 14mm end wrench and 5mm Allen key)
- Once removed, thread on provided nut (16mm).
- Tighten down bolt to 20lbs with 16mm End-wretch.
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his kit is designed to fit both the 120&160 engine platforms. The only difference you will find between the 120 and the 160 engine is the direction the cable adjustment block is installed on the engine block.
1. Remove the stamped factory linkage plate and related hardware.
2. Check your carburetor and confirm the throttle arm (black plastic molded arm on the top of the throttle shaft) is in good working condition.
3. Install the Linkage Bridge to your engine using the two supplied metric socket head bolts. A drop of thread locking compound on each bolt is recommended to prevent bolts from coming loose from vibration and harmonics.
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• Place the bike on the center stand and remove the current shock absorber.
• Place the Hyperpro shock in the bike, type 461 with reservoir as shown in the picture. If your shock is equipped with the optional hydraulic preload adjuster place the banjo bolt of the HPA to the right side of the bike.
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This pdf contains the ENGINE OVERHAUL 1994 ENGINE Chrysler Corp./Eagle/Mitsubishi 2.4L 4-Cylinder information.
Removal
1. Remove radiator shroud, cooling fan and pulley. Remove all drive belts and crankshaft pulleys. Remove
upper timing belt covers and gaskets. Note bolt length and location.
CAUTION: DO NOT rotate crankshaft counterclockwise (as viewed from timing
belt end of engine). If timing belt is to be reused, mark direction of
rotation before removing.
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Installation of the charging socket.
Ensure ignition is off and IMA battery switch under the rear cover is in the off position for at least 10 minutes prior to installation. Note the RED switch lock tab has to be removed to allow the IMA battery switch to be moved.
Remove all the IPU compartment cover star drive and 10mm bolts.
Remove the small 8mm black bolt from IMA Main Battery switch area. This is located to the right of the switch when looking in from rear of the vehicle.
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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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INSTALL FLYWHEEL
1. Drain 20% of the oil from the bike first.
2. Shut the gas supply off on the bike, then lay it over on its side. A small amount of gas will leak from the overflow tubes when the bike is first laid down.
3. Remove shifter.
4. Remove bolts holding the side cover on (no need to remove one of the oil filter bolts).
5. Remove oil fill cap.
6. Disconnect clutch cable and lay cable out of the way.
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TOOLS REQUIRED
Phillips screwdriver
Flat-tip screwdriver
Stubby Phillips screwdriver
10 mm combination wrench
Clip remover
8 mm and 10 mm Sockets
Ratchet
Small flat-tip screwdriver
Contact cleaner
Shop towel
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1 2 3 4 4 4 5 5 M12x75 M12x40 M12x40 M12x40 M12x40 M10x35 M10x35 M10x35 Washer ø32xø13×4 A A B B C D E F Clamp mark in acc. with ISO PN Cables joining 1 L Left directional lights 2 + Rear fog lights 3 31 Ground 4 R Right directional lights 5 58R Right side parking lights 6 54 Stoplights 7 58L Left side parking lights FITTING INSTRUCTION This towing hitch is designed to assembly in following cars: OPEL SINTRA produced since 1996 till 1999 and CHEVROLET TRANS SPORT, produced since 1997 till 2006, catalogue no. E49 and is prepared to tow trailers max total weight 2000 kg and max vertical load 75 kg. From manufacturer Thank you for buying our product. Their reliability has been confirmed in many tests. Reliability of towing hitch depends also on correct assembly and right operation. For this reasons we kindly ask
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Remove all items from the packing tube. You should have the following before beginning:
* (2) Gas springs (RT-QL-170-A6A) – Be sure to cycle them a few times before installing.
* (4) #2-3/16″ Multi-grip rivets (used on hood brackets)
* (2) ball-studs and washers each with a locking nut.
* (2) mounting brackets
* Printed Color Instructions
* Gas Spring locking clips – (Already installed in the gas spring ball-ends – Remove before assembly)
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