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King pin rear master cylinder cover kit. Not shown are (3) 6mm extra thick washers. The washers are used when installing master cover on a bike with a Tomahawk front highway bar |
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First remove the foot control . This can be done without removing lines. Remove the forward bolt first. |
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Now remove the aft bolt. This will be easier than the forward bolt but make sure you hold it so when it comes loose it does not rotate down and pop off the reservoir line for the rear master cylinder. |
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Now use something to support the foot controls (coffee can or wood ) so you don’t damage the lines. If the brake master line does pop off and brake fluid does get on the paint, push the line back onto the master cylinder and wash down brake fluid with water. Water will not damage your paint. You will need to bleed your brakes after install. |
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Now remove the forward master cylinder-mounting bolt. |
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Next remove the rear master cylinder-mounting bolt. |
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Now install one of the new socket cap rear master cylinder bolts that came with your tomahawk king pin rear master cylinder cover. Install the socket cap until it just pokes through the other side. IF THE BRAKE MASTER PUSH ROD POPS OUT WHEN INSTALLING YOU ARE NOT SCREWED, JUST PUSH IT BACK IN THROUGH THE BOOT AND MAKE SURE IT SEATS BACK INTO THE PLUNGER CUP AND INSTALL THE NEW SCOKET CAP. |
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Now install your tomahawk rear master cover. This can get dicey it is a very close fit. It maybe necessary to loosen the banjo fitting (pressure side of the master cylinder steel braided line) and re-index to make it easier to fit the cover over. |
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Now you have the cover on and past the lines. Check the alignment of the forward mounting bolthole. If it’s good, install the forwards mounting bolt and check the reservoir line and the pressure side line. |
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Now you have the forward and aft master cylinder socket cap mounting bolts just poking through the tomahawk master cover. You can tighten both forward and aft bolts to spec (SAE) |
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The tomahawk master cylinder cover will be loose when the bolts are both tight. Now install the 6mm nylocks and washers onto the forward and aft socket cap master mounting bolts and tighten to spec (SAE). The aft bolt behind the foot control floorboard is f—in difficult but not impossible to do, and you only have to do it once so suck it up. |
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You may need to use an allen wrench on the socket cap side of the master cylinder socket cap mounting bolts to keep them from backing out when tightening the nuts. |
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Now take the black silicone contact tape provided in your tomahawk rear master cylinder kit. Check the master cylinder reservoir line and install the black silicone tape onto the line where it may contact the master cylinder cover. Repeat this on the pressure line. The black silicone tape will minimize any contact. |
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Now start reinstalling the foot control fasteners. Make sure you use loctite on all fasteners that require loctite and always use the correct series loctite. Check you service manual or contact loctite direct for correct series for application. Inspect brakes for proper operations. If adjustment or fluid is needed consult service manual for proper adjustment and fluid. |