| A. Install Calipers |
| 1. Mount the calipers to the spindles using the included flange bolts. |
| Note: The proper way to install the calipers is with the bleeder screw angled UPWARDS and the brake line attachment downwards. View the two pictures below: |
(Top Photo) The bleeder screw is mounted upwards ( correctly)
(Bottom Photo) The bleeder screws are mounted downwards ( incorrectly)
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| B. Route Brake Lines |
2. The two shorter brake lines (27", with springs) are used for each side of the front suspension system. You will notice that one end of the brake line is sharply curved, and the other end terminates at a flat angle. Use the sharply curved ends on the calipiers, and the flat angled ends at the T-split. (see second picture below)
3.
The longer brake line (57") is used to connect the the T-split to the new master cylinder at the rear. Used the sharply curved end at the T-split, and the flat angle end at the master cylinder. |
Route brake lines away from any pinch points.
Drill to frame and mount T-split to frame.
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| B. Install Dual Master Cylinder |
4. Unbolt the master cylinder from it's two mounting bolts. Remove the bolts and replace with the longer bolts included in the kit. Position the original and dual master cylinder using the nuts and washers in the kit. Position these items as shown in the third image below. |
Unbolt the rear-brake master cylinder (leave it connected to the hydraulic line)
Replace the two master cylinder mounting bolts with the 2-1/2" bolts included in the kit.
These bolts will support the dual master cylinder setup.
Space the bolt shafts as shown using the supplied nuts and washers.
(Note: The picture shows the new master cylinder mounted on the inside near the bracket, but for installation purposes it is easier to install it on the outside, away from the bracket.)
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5. Install the new dual fluid reservoir. Use one of the original master cylinder mounting bolts that was removed in step 4. Use the nuts included in the kit, according to the picture below. |
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| C. Methods of Bleeding the Brakes |
The usual method of bleeding brakes (pump and release) doesn't work very well on Yerf Dog master cylinders. Vacuum-operated bleeder pumps are a great help and are available at any auto parts store. However, there is a simple way that doesn't require dishing out extra cash for a pump, and can be done with C-clip pliers (or needle nose pliers). We'll flip over the master cylinder and remove the internal piston, allowing gravity to bleed the system while our caliper bleeder screws are open. |
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| 6. Start the process by loosely mounting the new (front) master cylinder upside down on it's mounting bolts as pictured below. |
| 7. Disassemble the cylinder by removing the C-clip. The internal piston will spring out enough to allow you to grab and pull it out. |
| 8. Pour DOT-3 or DOT-4 brake fluid into the Front Brake reservoir, filling it to the upper line. Fluid will flow into the master cylinder. Move on to step 9 quickly as the fluid level rises in the master cylinder. Continue to replenish new fluid in the reservoir as the level lowers. |
Do NOT pour fluid directly into the open master cylinder. Only pour fresh fluid into the reservoir. This reduces the chance of air bubbles entering the system. |
| 9. When the fluid reaches the top of the master cylinder, insert the piston into the cylinder upside down (with spring facing upwards), just enough to prevent fluid from overflowing from the cylinder while gravity continues to bleed the brakes for us. |
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| 10. Open one of the front caliper bleeder screws. You should notice the fluid level in the reservoir diminishing, be sure to replenish the fluid without allowing the reservoir to empty. Within a few minutes, fluid should begin flowing from the caliper bleeder screw. Do not allow the fluid to contact the caliper body or brake pads. It's best to use a small clear hose to direct the fluid flow into a container. Allow the flow to continue until no bubbles come from the line. |
| 11. Repeat the last step with the other front caliper. |
| 12. Reassemble and install the master cylinder, and brake linkages. |
| 13. Check pedal pressure and brake function. With the front-end of the buggy supported, turn the wheels by hand and check that the front brakes work by depressing the brake pedal. The wheels should firmly and abruptly stop. |
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