Kirkham 427 Manual	Table of Contents

Pedal Box

Parts:

brake lever arm
clutch lever arm
pedal box pivot pin
pedal box pivot pin spacer
brake bias bar assembly
.700 master cylinder (2)
.750 master cylinder
master cylinder fittings (3)
return springs (2)
fastener kit
5/16-24 x 1.09” (4)
5/16-24 x 1.33” (4)
5/16-24 x 1.55”
5/16-24 x 2.73” (2)
5/16” washer (25)
5/16” jet nut (11)
3/8-24 x .81” (4)
3/8” washer (4)
top cover plate
bottom cover plate

Tools:

3/8” wrench
1/2” wrench
9/16” wrench
12mm wrench
needle nose pliers

Installation instructions

Step1: Detach the pedal box fromthe frame. Discard the bolts that previously held it to the frame as new ones are provided in the kit.

Step 2: Attach the master cylinders. Of the two master cylinders stacked on top of one another, the top is the front brake, and the bottom is the rearbrake.

Step3: Use the two 5/16-24 x 2.73 bolts to bolt in the bias guide. These bolts will hold the master cylinders as well.

Step4: Brake pedal assembly. Do not tighten these bolts. Just run them down to the point where the pieces still pivot. Note the return spring holder on the middle bolt.

Step5: Clutchpedal assembly. Again, do not tighten the bolt. Just run it down.

Step 6: Install the pedal assemblies onto the master cylinders. Do not worry about fine tuning the throw or alignment yet. Just get them in the ballpark for now.

Step 7: Install the pivot pin. Place the spacer between the two pedals, and use the shims provided to properly align the pedals into place. Fasten the pivot pin in with the big cotter pin.

Step 8: Install the return springs. Hang them from the return spring holders on each pedal to a cotter pin. Slide the cotter pins through the two holes, and bend each end of the cotter pins through the holes, and bend each of the pins out on the outside of the box.

Step 9: Install the o-ring fittings. Use oil on the o-rings so they'll slide in the taper more easily. Also, if your master cylinders came with fittings where the red caps are located, discard them as you will not need them.

Step 10: Fit the top cover to make sure everything lines up well and does not rub on anything.

Step 11: Install the bottom cover plate.

Step 12: Completed pedal box. Make sure to align and adjust the pedals. Tighten the master cylinder jam nuts with a 12mm wrench.

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Req. from 38.107.191.100 on Tuesday, 07-Sep-2010 16:19:11 GMT
Change date: Monday, 02-Jul-2007 20:58:39 MDT
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