RS424 INSTRUCTIONS - RevZilla · RS424 INSTRUCTIONS TO BE INSTALLED BY A CERTIFIED MECHANIC ONLY |...
Transcript of RS424 INSTRUCTIONS - RevZilla · RS424 INSTRUCTIONS TO BE INSTALLED BY A CERTIFIED MECHANIC ONLY |...
BRAKE LEVER TOE PEG OPTIONS - TOP VIEW
TOE PEG MUST FOLD TOWARDS FOOT PEG
RS424 INSTRUCTIONS
1.800.440.3559www.VORTEXRACING.com
TO BE INSTALLED BY A CERTIFIED MECHANIC ONLY | FOR RACE USE ONLY
RS681DRK
RS424DK
RSP01K
RS424EK
RSP04AK
F-116SH8 X 20 SHCS
F-100BH10 X 25 BHCS
F-117SH8 X 16 SHCS
F-101S
F-106NW
Red Thread Lock
DO NOT Overtighten
Use Factory Piece
Lubricate
INDEX
BRAKE SIDE EXPLODED VIEW
F-117SH8 X 16 SHCS
BRAKE LIGHT INFO:These rearsets do not use: OEM rear brake light switch, spring & lever return spring. In race form these rear sets no longer activate rear brake light from rear brake lever. Street use requires rear brake light to be activated by rear & front brake levers. To achieve rear brake light activation from rear brake lever use Vortex in-line pressure switch RS100.
RSP08
RSP02
RSP12
H-101CL
RSP09K
F-108FH
RSP03
SEE SPECIAL BRAKEINSTALLATION INSTRUCTIONS
FOR DETAILS
FOR: KAWASAKI NINJA 250 08-10
RS424 INSTRUCTIONS
1.800.440.3559www.VORTEXRACING.com
TO BE INSTALLED BY A CERTIFIED MECHANIC ONLY | FOR RACE USE ONLY
RS424ARK
RS424AK
RS424BK
RSP04AK
F-100BH10 X 25 BHCS
F-117SH8 X 16 SHCS
Red Thread Lock
DO NOT Overtighten
Use Factory Piece
Lubricate
INDEX
SHIFT SIDE EXPLODED VIEW
F-101S
RSP08
RSP01K
RSP02
RSP12
H-101CL
RSP09K
F-108FH
RSP03
F-117SH8 X 16 SHCS
F-106NW
FOR: KAWASAKI NINJA 250 08-10
SHIFT LEVER TOE PEG OPTIONS - TOP VIEW
TOE PEG MUST FOLD TOWARDS FOOT PEG
RS42
4 IN
STRU
CTIO
NS
1.80
0.44
0.35
59w
ww
.VO
RTEX
RACI
NG
.com
TO B
E IN
STA
LLED
BY
A C
ERTI
FIED
MEC
HA
NIC
ON
LY |
FOR
RACE
USE
ON
LY
SPEC
IAL
BRAK
E SI
DE
INST
RUC
TIO
NS
Kaw
asak
i Nin
ja 2
50R
– Br
ake
side
M
aste
r cyl
inde
r ins
tall
inst
ruct
ions
Due
to th
e po
tent
ial s
afet
y ha
zard
s in
volv
ed w
ith th
is in
stal
latio
n Vo
rtex
reco
mm
ends
that
this
inst
alla
tion
ON
LY b
e pe
rfor
med
by
a ce
rtifi
ed m
echa
nic.
Fai
lure
to in
stal
l the
se p
arts
pro
perly
may
re
sult
in c
rash
, inj
ury
or d
eath
.
STO
CK R
EMO
vAL
1 Lo
cate
and
loos
en (b
y O
NLY
¼ tu
rn.
Just
eno
ugh
to
br
eak
it lo
ose)
the
banj
o bo
lt on
top
of th
e re
ar b
rake
mas
ter c
ylin
der
2 Re
mov
e th
e en
tire
brak
e si
de h
eel g
uard
, peg
, and
leve
r ass
embl
y (2
bol
ts).
3 Ca
refu
lly re
mov
e th
e co
tter
pin
on
the
back
of t
he h
inge
pin
conn
ectin
g th
e m
aste
r cyl
inde
r to
the
brak
e pe
dal.
Push
out
the
hing
e pi
n to
rele
ase
the
peda
l fro
m th
e
mas
ter c
ylin
der.
4 Re
mov
e th
e re
ar m
aste
r cyl
inde
r fro
m th
e he
el g
uard
(2 b
olts
).5
Rem
ove
the
rear
bra
ke fl
uid
rese
rvoi
r fro
m b
ehin
d th
e
pa
ssen
ger f
oot p
eg.
Dra
in a
s m
uch
brak
e flu
id a
pos
sibl
e
in
to a
con
tain
er.
Onc
e m
ost o
f the
flui
d is
dra
ined
rele
ase
the
hose
lead
ing
to th
e re
serv
oir f
rom
the
mas
ter c
ylin
der
by
squ
eezi
ng th
e sp
ring
clip
with
plie
rs a
nd s
lidin
g it
one
inch
up
the
hose
. N
ext,
gent
ly p
ull t
he h
ose
off th
e in
let
to
the
mas
ter c
ylin
der.
6 Re
mov
e th
e ba
njo
bolt
that
was
loos
ened
in S
tep
1.
M
ake
sure
to h
ave
som
ethi
ng re
ady
to c
atch
any
rem
aini
ng fl
uid.
7 Th
row
aw
ay th
e tw
o st
ock
banj
o bo
lt w
ashe
rs.
Th
ese
are
a on
e tim
e us
e pa
rt a
nd m
ay le
ak if
re-u
sed.
16 7
7
4
4
5
3
2
RS424 INSTRU
CTION
S
1.800.440.3559w
ww
.VORTEXRACIN
G.com
TO BE IN
STALLED
BY A CERTIFIED
MECH
AN
IC ON
LY | FOR RA
CE USE O
NLY
SPECIAL BRAKE SID
E INSTR
UCTION
Sv
ORTEX IN
STALLATIO
N
Pre-assemble the brake pedal onto the heel guard, and the reloca-
tor plate to the frame before continuing.
8 Rotate the rear m
aster cylinder 180 degrees compared to
how
it came off the bike. The inlet tube should now
face
towards the rear caliper.
9 M
ount the master cylinder to the Vortex heel guard using
the 8x20 bolts included. U
se thread locking compound to
reduce the chance vibratory loosening.
10 Install the hinge pin though the m
aster cylinder clevis and
brake pedal from the front side. Install the cotter pin
through the hole in the hinge pin and bend the arm
s to lock
everything together.11
Mount the heel guard assem
bly to the relocator bracket on
the frame using the 8x16 bolts supplied. U
se thread locking
compound to reduce the chance vibratory loosening.
12 Reattach the supply hose from
the reservoir to the master
cylinder w
ith the spring clip. Some foot positions m
ay re
quire shorting the hose. Use caution w
hen trimm
ing the
hose and insure tha it is still long enough to reach the
master cylinder in all foot positions.
13 Find the tw
o crush washers that w
ere supplied with the
rearset kit. Place one N
EW crush w
asher on EACH SID
E of
the brake line. 14
Install the banjo bolt and torque to 22 ft-lbs. DO
NO
T OVER
TIG
HTEN
. Doing so w
ill cause the banjo bolt to fail.15
Fill and bleed the rear brake system according to the
m
anufacturer’s specified procedure. 16
Once com
plete thoroughly wash off any spilled brake fluid
using w
arm w
ater and liquid dish detergent.17
Check the system for proper operation prior to riding the
m
otorcycle.
14
8
9
1313
9
11
10
12