User's Manual

10. Brake Light Switch:
The KDX uses a hydraulic brake
switch. This requires replacing
the rear master cylinder banjo
bolt with a specially made
switch. Installing the switch
requires bleeding the rear brake.
If you do not feel competent
bleeding your rear brake, please
refer this job to a qualified
mechanic as failure to do it
correctly will render the brake
inoperable.
Remove the bolt holding the
brake fluid reservoir to provide
access to the master cylinder.
Loosen the banjo bolt that secures the rear brake line to the master cylinder. Typically,
this bolt will be very tight and loosening it will bend the hanger for the master cylinder if
not supported.
Photo 5
Remove the banjo bolt and replace with the hydraulic switch. You may need to bend the
tab that mounts the reservoir back slightly to make clearance for the brakeswitch. Make
sure to install the copper crush washer from the stock bolt under the switch. Torque
the switch assembly to 25 lbf-ft. Once the switch is installed, reattach the reservoir using
the provided extension bracket as shown in Photo 5.
Locate the red and blue wire extension in the parts bag. Attach the end with both females
to the two males from the brakeswitch. Route this extension up the subframe to the area
behind the airbox. We’ll attach this extension to the wiring harness in a later step.
Bleeding the Brakes: (Do not begin this
process unless you have a fresh can of
brake fluid) Re-install the brake fluid
reservoir and
remove the lid. Put the box end of 8mm
wrench over the brake bleed nipple and
install the bleed hose (supplied) tightly over
the nipple. Position the loop on the hose
above the nipple as shown in Photo 6 with
the other end of the hose in a container to
catch the fluid. Crack the bleed nipple open
about 1/8 to a quarter turn keeping the loop
in the hose vertical. Slowly depress the
brake pedal to fill the hose with fluid. Pump slowly until you have brake fluid extending
up into the loop, then you can pump the pedal fairly aggressively to drive air out of the
system - The fluid above the bleed nipple will prevent air from re-entering the system.
DO NOT LET THE RESERVOIR GO DRY - ADD FLUID AS NEEDED. Pump the
pedal until there is no more bubbles, then close the nipple with the wrench. Double
check that the pedal is firm and the brake works properly.
Keep loop
above
bleed nipple
Bleed Nipple
8 mm Wrench
Container
Photo 6
6