Universal Motorcycle Foot Rear Brake Master Cylinder Tank Oil Cup Fluid Bottle Reservoir User Manual

Introduction

This manual provides essential information for the installation, operation, and maintenance of your FLYPIG Universal Motorcycle Foot Rear Brake Master Cylinder Tank Oil Cup Fluid Bottle Reservoir. Please read this manual thoroughly before installation and use to ensure proper function and safety.

Product Overview

The FLYPIG Universal Brake Fluid Reservoir is designed as a replacement or upgrade for various motorcycle and ATV models. It is constructed from durable plastic and serves to hold brake fluid for the rear brake system.

Figure 1: Front view of the FLYPIG Universal Brake Fluid Reservoir, showing its translucent plastic body and black cap.

Figure 2: Technical drawing illustrating the dimensions of the brake fluid reservoir, including length, width, height, and hose connection diameter.

Figure 3: Close-up view highlighting the metal material of the mounting eyelet, indicating enhanced stability.

Figure 4: Top view of the reservoir, showing the black cap with "USE ONLY DOT3 OR DOT4 BRAKE FLUID" warning text and screw fasteners.

Specifications

Compatibility

This universal brake fluid reservoir is designed to fit most motorcycles and ATVs. However, please note that it may not mount exactly like the original equipment manufacturer (OEM) part. Adaptations to mounting may be required for proper fitment.

Important: Verify the size of your current reservoir to ensure a proper fit, this reservoir measures 8mm or 0.315 inch in diameter for the hose connection. Hose size may vary by application; in some cases, the existing hose may be smaller and require tightening for a secure fit.

Known Compatible Models (Examples):

• Honda ATV: 1983-87 ATC200X, 1983-86 ATC250R, 1985-86 ATC350X, 1987-92 Fourtrax 250 TRX250X, 1993-08 Sportrax 300 TRX300EX, 1999-08 Sportrax 400 TRX400EX
• Kawasaki ATV: 1995-03 Lakota 300 KEF300, 1987-03 Mojave 250 KSF250, 1986-87 Tecate KXT250
• Suzuki ATV: 1985-93 Quadrunner 230 LT230E, 1985-87 Quadrunner 250 LT250E, 1985-88 Quadsport 230 LT230S, 1989-90 Quadsport 250 LT250S, 1985-92 Quadracer 250 LT250R, 1987-90 Quadracer 500 LT500R
• Kawasaki Offroad Bike: 1995-06 KDX200, 1997-05 KDX220R, 1991-94 KDX250, 2000-03 Super Sherpa 250 KL250, 1994-96 KLX250, 1994-96 KLX250R, 2006-12 KLX250S, 2009-10 KLX250SF, 1997-03 KLX300, 1997-07 KLX300R, 1993-96 KLX650, 1992-96 KX125, 1992-96 KX250

Note: If your OEM part number is 43511-HA2-016, this product is not a direct replacement.

Setup and Installation

Installation of the brake fluid reservoir requires mechanical aptitude and familiarity with motorcycle/ATV brake systems. If you are unsure about any step, it is recommended to seek professional assistance.

General Installation Steps:

1. Safety First: Ensure the vehicle is stable and cool. Wear appropriate safety gear, including eye protection.
2. Drain Old Fluid: Carefully drain the old brake fluid from the master cylinder and reservoir system. Dispose of brake fluid responsibly.
3. Remove Old Reservoir: Disconnect the hose from the old reservoir and unmount it from the vehicle.
4. Prepare New Reservoir: Inspect the new FLYPIG reservoir for any damage.
5. Mount New Reservoir: Attach the new reservoir to the vehicle. As this is a universal part, you may need to adapt the mounting to fit properly. This could involve slight adjustments to the mounting bracket or using spacers.
6. Connect Hose: Connect the brake fluid hose to the reservoir's outlet. Ensure a tight fit. If the hose is slightly larger than the reservoir's outlet, it may need to be tightened securely with a clamp to prevent leaks.
7. Fill with Fluid: Fill the reservoir with new, clean DOT3 or DOT4 brake fluid as specified by your vehicle manufacturer. Do not mix different types of brake fluid.
8. Bleed Brake System: Bleed the entire rear brake system to remove any air. This is a critical step to ensure proper brake function. Refer to your vehicle's service manual for specific bleeding procedures.
9. Check for Leaks: After bleeding, thoroughly check all connections for any signs of fluid leaks.
10. Test Brakes: Before riding, test the brake system in a safe, controlled environment to confirm proper operation.

Operating Considerations

Once installed, the brake fluid reservoir operates passively as part of your vehicle's hydraulic brake system. Its primary function is to hold the brake fluid supply for the master cylinder.

• Fluid Level: Always ensure the brake fluid level is between the "UPPER" and "LOWER" marks indicated on the reservoir.
• Fluid Type: Only use DOT3 or DOT4 brake fluid as specified on the reservoir cap and by your vehicle manufacturer. Using incorrect fluid can damage the brake system.

Maintenance

Regular maintenance of your brake system, including the fluid reservoir, is crucial for safety and performance.

• Fluid Level Check: Periodically check the brake fluid level in the reservoir. A low level may indicate a leak or worn brake pads.
• Fluid Condition: Inspect the brake fluid for discoloration or contaminants. Brake fluid should be clear or slightly amber. Dark or cloudy fluid indicates it needs to be replaced.
• Fluid Replacement: Follow your vehicle manufacturer's recommendations for brake fluid replacement intervals. Brake fluid absorbs moisture over time, which can reduce braking performance and damage components.
• Reservoir Cleaning: Keep the exterior of the reservoir clean to easily monitor fluid levels and detect any leaks.
• Hose Inspection: Regularly inspect the hose connecting the reservoir to the master cylinder for cracks, kinks, or signs of wear.

Troubleshooting

If you encounter issues after installing the reservoir, consider the following:

• Fluid Leaks:
  • Ensure all connections, especially the hose clamp, are securely tightened.
  • Check for cracks in the reservoir or hose.
• Improper Fitment:
  • If the reservoir does not mount perfectly, minor adaptations (e.g., bending a bracket, using a spacer) may be necessary due to its universal design.
  • Verify the hose diameter. If the existing hose is too loose, ensure it is properly clamped or consider a hose with a tighter fit.
• Spongy Brake Pedal/Lever:
  • This usually indicates air in the brake system. Re-bleed the brake system thoroughly.
  • Ensure the reservoir was not allowed to run dry during the bleeding process.
• Brake Fluid Contamination:
  • If the fluid appears discolored or contains particles, the system may need to be flushed and refilled with new fluid.

For persistent issues, consult a qualified mechanic.

What's in the Box

The package includes:

• 1x Rear brake reservoir

Warranty and Support

For any product-related inquiries or support, please contact the manufacturer, FLYPIG, through their official channels or the retailer from whom the product was purchased. Specific warranty details may vary by region and retailer.