Well, I solved the problems with mounting the master cylinder yesterday. Because I still have the stock handlebars and the stock cover my situation was a little different than Nexus'. I removed the little black cylindrical cover between the handlebar cover and the start/stop switch console. Then I used a hacksaw to
carefully cut off the tabs on the end of the handlebar cover. Realizing that if I scored the bar it could break under heavy pressure.
Now the more
complicated part: I machined the spacer to space the
master cylinder mount forward from the bar. Nexus had indicated that he also did this but it looked like I needed even more spacing. The spacer has to have a
radius of 7/16" (
dia.
7/8") on both the outside and inside. So when looking at the end of the spacer it looks like a
crescent moon. At the thickest point it is 3/8", therefore spacing the
master cylinder 3/8" ahead of the front of the handlebar. Of course I now had to replace the
original clamping bolts with longer 6mm bolts.
In Nexus' photos you can see that he ground a
chamfer on the part of the hand lever that holds the bolt that pushes on the hydraulic plunger. I had to do that also in order to clear the start/stop
sw
console. Also the adjustment bolt that pushes on the hydraulic plunger has to have the head portion cut off. The bolt is then slotted with a hacksaw to make it into a set screw. Or the bolt can just be replaced with a 6mm x 20mm socket set screw. I chose the former.
It seemed funny yesterday evening, riding home from my shop with a hand brake the was not connected to anything. Good thing I didn't try to use it to stop.:)
Now I'm on to the tougher part of this project - the slave cylinder mounting & the clevis, etc., etc. :pray: