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Messages - 2ballde

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1
You can get a banjo bolt w/switch and use it to replace the non switch bolt on the master cylinder. Just make sure you get the correct thread. This one that might work; https://www.amazon.com/gp/product/B000GTX0XE/ref=oh_aui_detailpage_o00_s00?ie=UTF8&psc=1

2
Zero Motorcycles Forum | 2013+ / Re: Front brake lever
« on: June 25, 2017, 07:03:56 AM »
Maybe you could contact JJuan in Barcelona, SP. to buy parts for the master cylinder shown in the 4th. row on this page; http://jjuan.es/by-product-type/master-cylinders-2/?lang=en there must be JJuan dealers that would sell parts. This would bypass ZERO and might be faster. When I moved my rear brake control to the handlebar it bothered me having different master cylinders on the handlebar( one triangle, one rectangle) and there  are many Brembo master cylinders available to replace the JJuan

3
rayivers is on to something as maybe this is a common FX problem. If the rear brake system is properly bled. You could mount the separate switch where it is most practical, cut the extra long spring to the length you need for proper actuation. The stock sw. wires go to a connector on top of the motor( on an SR). Cut the wires, connect up to the wires on the new mechanical sw. and you have an adjustable sw. you can have activate where you want it to for the brake light and the ABS just like the hydraulic sw,. Just leave the hydraulic mc,/sw. as is to avoid re-bleeding. Over the years I've re-purposed various simpson metal brackets( found at most hardware stores) for mounting stuff to motorcycles. A little paint and they look fine.

4
The rear brake switch is activated hydraulically by pressure in the rear brake system. It could be you have some air in the rear system and needs extra lever pressure to close the switch. The threaded rod from the brake lever to the master cylinder adjusts lever height. This a SR rear mc no adjustments except for lever height. Switch is built into top banjo bolt.
 

5
Zero Motorcycles Forum | 2013+ / Re: Left Hand Rear Brake Install
« on: January 19, 2017, 01:06:29 AM »
My left hand rear brake install is done and working good. After the first brake light switch failed, re-bleeding  the line wasn't working. Power bleed, mighty vac, and old school hand lever press and caliper release all resulted in a mushy feel. On this page; https://www.revzilla.com/common-tread/video-how-to-bleed-motorcycle-brakes  there was a method I never heard of. Basically, compress the hand lever to the bar with a zip tie or lever lock, and leave over night. This worked well for me tho' I read elsewhere that it doesn't work. If your having trouble bleeding a brake it's worth a try.

6
Zero Motorcycles Forum | 2013+ / Re: Left Hand Rear Brake Install
« on: January 05, 2017, 12:46:48 AM »
Clay, yes a brake line like the front brake, run to the ABS unit and an extension from the rear brake sw. uses the shortest brake line path. The ABS unit is between the frame spars right behind the steering tube. Getting a wrench in there  and then retorquing the banjo bolt is a bigger pia than I wanted to undertake. So the the long brake run and short wiring mod. I'm sure bleeding the shorter line would be easier.


7
Zero Motorcycles Forum | 2013+ / Re: Left Hand Rear Brake Install
« on: December 29, 2016, 09:08:27 AM »
After further investigation the drawing above is a Bosch ABS-N unit.

8
Zero Motorcycles Forum | 2013+ / Re: Left Hand Rear Brake Install
« on: December 25, 2016, 07:13:08 AM »
Notes from a left hand rear brake project. Can't fabricate parts so easy since retiring, so quit the cable-to rear master cyl. method. I measured the front MC piston (13mm), rear MC (12mm) and front caliper (30 & 32mm) Rear caliper (34mm). Banjo threads on front MC 10mmx1.0, rear MC 10mmx1.25. Since I was eliminating the rear MC and had a 10mm x 1.0 180 deg. manifold had to buy a Tusk  hydraulic switch. I used a Brembo clutch MC, a custom Speigler hose (1422mm long) with a 90 deg. and a short straight on either end. Put it all together, bled the system. It felt good in the garage test mode. Unfortunately the tusk was weeping out of the wires. They are sending another no charge,no return of the faulty one. I would bypass the brake sw. but I think it may activate the ABS as well as the brake light. It's been snowing so not completely bummed at the delay. I'd love to see an electrical schematic but they seem as rare as service manuals. The drawing may or may not be a Gen9 ABS but is probably typical

9
Probably a simple oversight. Noticed today that the FX/FXS owners manual has the 40ft/lb but the pinch bolts are 9.5 ft/lb. The FX has 41mm Showa forks with a couple inches more travel. The 16ft/lb torque is more in line for the 8mm pinch bolts that the '16 SR has. 9.5ft/lb for 6mm bolts.

10
The email from ZERO

11
Zero Motorcycles Forum | 2013+ / 2016 SR front axle w/17mm socket torque
« on: December 13, 2016, 03:09:43 AM »
Samir C. Mohammed at ZERO got back to me quickly with the following update. On 2016 and probably bikes with the Showa forks with axles w/17mm socket on the end and the 6mm socket head pinch bolts, 40ft/lb for the axle and 16ft/lb on the pinch bolts.
Thanks Samir.

12
Zero Motorcycles Forum | 2013+ / Re: 2016 SR front wheel removal
« on: December 12, 2016, 08:34:30 AM »
Manual torque is for axle end bolts, 2016 SR has no end bolts only a 17mm socketed rightside of shaft that threads into the left side fork leg.. 75 ft/lb seems a little high, looking at other manuals the torque hovers either side of 50 ft/lb. Will check with ZERO. Will say other requests for specifications haven't yielded satisfactory answers.

13
Zero Motorcycles Forum | 2013+ / Re: 2016 SR front wheel removal
« on: December 12, 2016, 06:49:18 AM »
Thanks for the torque value. ZERO is the first bike I ever owned I couldn't get a service manual for. Guess they are worried about shock hazard.

14
Zero Motorcycles Forum | 2013+ / 2016 SR front wheel removal
« on: December 12, 2016, 03:59:04 AM »
Couldn't find any info on front wheel removal so I'll go through how i did it. Loosen axle pinch bolts( 6mm allen), then loosen axle(17mm allen). These are best loosened with the wheel solidly on the ground. Loosen brake pad retaining pin(T25 torx) don't remove all the way pull out inner brake pad, the pad seems to prevent the caliper from clearing the brake disc then screw in the pin a few turns, this makes reassembly a lot easier. Remove allen bolts holding the caliper on. I also pulled the ABS cable away from the brake line so the ABS sensor and the caliper could hang separately. Remove caliper.  Lift bike's front wheel off the ground. Remove axle. Pull wheel out. Reverse steps for install. This is different than the method in the unofficial manual, maybe different years and parts. The owners manual I got with the bike also mentions front axle bolts that aren't on the 2016 SR. I'm going to use standard bolt size torques for now. I'm not sure what to torque the axle to. I'll check with my dealer.

15
Zero Motorcycles Forum | 2013+ / Re: Left Hand Rear Brake Install
« on: December 06, 2016, 07:26:11 AM »
The hose connecting method above with the manifold allows reuse of the stock rear brake light switch.

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