BRAKE CONVERSION KIT - VERSYS 650 - Installation

Please note: this brake conversion kit should only be fitted by an experienced motorcycle mechanic due to the critical function of these parts.

 

Remove the brake lines from the standard calipers, taking care to catch/mop-up any spilt fliud.

 

Remove the calipers. You will need to reuse the rhs double banjo-bolt for the new caliper.

 

Assemble the pads (with the respective anti-squeal shims ) and retaining plates into the callipers.

 

The mounting brackets are loosely pre-assembled to show you their orientation but the bolts will need to be removed and thread-lock applied. They can only be fully tightened once the whole calliper assembly is mounted to the bike.

 

Mount the calliper assemblies to the fork legs, again, you will need to apply suitable thread-lock to the bolts – apply a torque of 33Nm/25lbft to the bolts.

 

Check the callipers are centre to the disc then fully tighten the retaining bolts to 33Nm/25lbft.

 

Next stage is to reconnect the brake lines. These are refitted as the standard configuration, using the new brass washers. loosely assemble the lines until you are happy with their routing then apply a torque to the banjo-bolts of 12Nm/9lbft. 

 

Attach the bleed valve (provided) to the rhs nipple first and slightly crack it open – open it too much and fluid will leak past the threads. Let the loose end of the bleed valve sit inside an empty jar to catch the fluid.

 

Remove the reservoir top and refill it, then slowly fully compress the brake lever several times until the fluid coming out of the nipple is free of air bubbles. Monitor the fluid level in the reservoir and top-up as necessary.

 

Repeat the procedure for the lhs calliper.

 

Make sure the fluid level in the reservoir is at the recommended level and replace the cover.

 

If all the air is removed from the system, the brake lever will have a firm feel. To double check all air is removed, fully apply the brake lever and using tape or zip-tie, fix the lever in this position and leave overnight. This will allow any trapped air bubbles to surface.

 

Double check the entire installation before test riding.

 

Take extra care during the next 100 miles whilst the brakes bed themselves in, to provide full braking performance.