2004-2008 Honda CBR1000RR Galfer Brake lines Installation Instructions
Install Galfer Brake lines after HeliBars® are installed. Carefully follow their instructions.
A. Before the factory bars are removed:
1. Carefully loosen the clutch hydraulic line banjo bolt at the clutch master cylinder just enough to rotate the steel banjo fitting forward. (See photo A for positioning). Additional fine adjustments may be required after installation of HeliBars. This modification is necessary for the new bar location / hydraulic line clearance.
B. Remove front brake hydraulic lines (longer stainless steel brake lines are provided). Cover or plug open banjo bolt holes.
CAUTION: Hydraulic brake fluid is extremely corrosive to paint and plastic. Additional instructions are provided with the Galfer brake lines.
1. Completely drain front brake hydraulic system.
2. Detach front brake hydraulic line from master cylinder. Cover or plug open banjo bolt hole. Remove the clamp that holds the line to the lower triple clamp.
3. Remove the bolt that attaches the brake line junction (photo 1) to the right side of the front fender and save with stock brake line.
4. Remove the clamp that holds the left caliper line to the left side of the fender. (Photo 2) Reinstall the nut only and tighten. This will protect the new line from chafing.
5. Remove the left and right banjos from the calipers. Cover or plug open banjo bolt holes.
C. Remove the stock handlebars. It will be necessary to temporarily move the electronic steering stabilizer out of the way. Refer to the factory manual.
1. Remove the damper weights at the end of both bars. REFER to the attached sheet “Removing Damper Units from Stock Handlebars”. Use a large T handle Phillips head wrench while carefully holding the damper weight from rotating.
2. Remove top triple clamp.
3. Remove all controls from the stock bars. Note the location of cables and line. Remove stock clipons.
4. Remove wire circlips from both fork tubes located just beneath the bottom edge of the stock clipon clamps. They will not be reused.
5. Install throttle on to the right side HeliBar and slide over the right fork tube. Lightly tighten pinch bolts. Reposition the starter / kill switch housing wire loom behind the right fork tube and install control on to bar. Tighten. 6. 6. Install front brake master cylinder. Use caution to avoid marring the powder coat finish. With the HeliBar design, the throttle housing is repositioned to allow additional slack. The throttle position is 110 degrees clockwise from stock putting the cables below the front brake master cylinder.
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