SM2 bars.. having a hard time with the brake reservoir housing

[Bluehaze]

Anyone have any pictures of how i am to put the brake thing back on?  When you screw it in..is it flush with the bars?  From the website it shows that you are supposed to twist it lower.. however.. i do that its still not flush with the bars.. and it shows that i have no brake fluid.. its total white..  please if anyone has pictures to help me out.

thanks.

[The Buddha]

Does the brake banjo hit the dash ? That is an issue I have heard of, otherwise - I dunno, never had SM's.
Cool.
Buddha.

[scotilac]

I'm having the same problems with the master cylinder hitting the dash. How can I fix this. I have just payed my local dealership to tell me they don't fit?

[Bluehaze]

so seriously with a techwiki on SM2 bars.. Scott and I are the only ones that bought this thing and tried to install??? there has got to be another one in this forum that has done so. I have checked out Pablo's web page but it is also very vague... 

[average]

No your not. I had the same issue when I had them. The only thing i can tell you guys is tio rotate it down abit. I honestly didn't really need to rotate mine at all I just pushed it as close to the guages as it would go and dealt with it and never had a problem.

[merisey]

mine are real close but the banjo does not touch... had to do a little moving and turning. I think I only actually pulled the bars down more.... did it durring the end of last summer, sorry don't quite remember everything.

[Bluehaze]

you guys mind posting up some close up pictures? of the banjo fitting and on the bars how it is connected?

[Bluehaze]

ok scotilac good news. at least for me..     so after messing with this some more i found my problem.   u see the bar was not far enough down. i didnt realize that you have to push the gauges down so that you can push the bars down some more..  so first pic show the bars in the wrong position. Thus when i force the brake reservoir on..it was still on top of the gauge and did not feel right. 

Wrong position: As you can see its above the gauge.



Later i found you just needed to push the gauge down. And this is the correct way.





By doing this i was able to just insert the brake reservoir with no problem. It is still tight but will fit.





Question as you can see by the reservoir.. its showing that it needs fluid..but really its just bent down a bit more...  is that ok? Anyone who knows?

Scotilac ... maybe you can show them your dealer these pictures..

[The Buddha]

I have thought this a 1000 times ... never have I said it - maybe its a trade secret, maybe its blingier, maybe its ... dunno common sense ... or lack there of.
Why the F*(k didn't they miter that weld also instead of notching it. I miter both of mine, and the result is a bit more freedom of rotation. Mine can be rotated down till they hit the top triple, they will never contact the dash. I also think mine are a wee bit wider in the center.
Cool.
Buddha.

[joker79507]

Question as you can see by the reservoir.. its showing that it needs fluid..but really its just bent down a bit more...  is that ok? Anyone who knows?

It should be ok as long as the brake still gets full fluid while using it.  If the hose is at the lowest point of the reservior with it turned like that you will be fine but if its back (towards the rider) a little more that the lowest point I would test it out on streets not going fast and make sure it still gets plenty of fluid.  It still should be fine, its not like your supposed to brake while turning anyway

[scotilac]

Amazing. Thanks for the pictures bluehaze. I have had it with the dealership and I think I will give it a shot myself. Thanks for the help, this fourm is amazing!!!

[Bluehaze]

Then  let me tell you a few things scotilac to ease your mind when you do it.

I am assuming that your bike is 04-08  range.. as this is similar to my bike

1.  Make sure you have the GS500  Hayesservice manual.  Actually it could possibly another brand...this is just the one i used. and Read through the whole procedure first.

2. You need metric tools.  an  8mm for the reservoir  and the clutch .  6mm allen wrench for the clamps.  a very small flat head screwdriver for the caps. *important. ensure you use metric allen wrench.. 

3. Read the whole thing!!!  The left side grip is hard to take off..   i ended up using wd40  with the hose and sprayed in there..  worked like  a charm.  However... i was not planning on reusing my grips .. i bought another type... This may not be a good idea if you plan to reuse the grip.    Someone else can chime in on how to on this.   

4. You actually don't have to take the clutch cable off as stated in the manual.. All i did was untighten the screw on the handle bar... then i  finished the procedure for the brake reservoirc and the right side.. then i unhooked the bar from the clamps.. and slid off the whole clutch  assembly.

5. When you get the brake reservoir off..  try to keep it level and not putting pressure on the line..  use another person.. or in my case i used those clothes hanger that made of somewhat stiff wire but you can bend and manipulate... i  wrapped it around my mirrors and it held up the reservoir fine.     this one is hard to explain..   but i search the forum..and people said.. you need to ensure to keep it level as much as possible and  not putting pressure on the brake line going down.

6. two black screws are the ones to unscrew on those switches..  i unscrewed others.... it was not a bad thing..but this can save you the trouble..

7. be mindful of the small wires that are connected to your brake lever and your clutch lever.  you need to take them off

8. you will need to fish out the rubber that holds the end weight in once you unscrewed them out.  on both side..

Well that is all the things i can think of that should make it easy for you.   

[joker79507]

I used a lubricant to also take off the left grip.  I reused it but before I put it on it back on I cleaned it real good.  I had to use a twisting motion to get it off and it was hard.  Putting it back on was actually easy though.  I used my palm on the outside and held the bike and just pushed it on.  You will get it.  I also reused the end weights.  I had to take off one of the nuts because it was to big to fit in the vortex bars and I also had to shave a bit of the rubber off to make it slide in.  If you reuse the end weights and trim the rubber make sure the rubber is just thin enough to force the weight in and then screw it down.  It took me a few times but I got it.

Once again, make sure the rubber goes in tight and then screw it down.  If not the weight will slip out and you will lose it.