Edelbrock Russell R09783 User manual

©2006 Edelbrock Corporation
Rev. 7/06 - BC/mc
Catalog #R09783
Brochure #63-R09783
Page 1 of 2
Catalog #R09783
DOT Racer Front Brake Hose Kit
for 2006 Yamaha YZF-R6
INSTALLATION INSTRUCTIONS
1. Remove factory brake hose assembly and related hardware, noting routing. Plug master cylinder and caliper
ports.
2. For easier hose installation, mark master cylinder orientation on handlebar and remove.
3. Unplug horn and remove horn bracket/dust shield assembly from fork tree and then remove horn from bracket.
4. Bend brake hose junction block locating tab on horn bracket flat for hose clearance
(See Fig. 1).
5. Install side-bent banjo end of Russell right-side hose onto caliper so that banjo bends around front of locating tab
(See Fig. 2). Locate hose to fork with factory bracket around hose grommet.
6. Install slight-bent (20°) banjo end of Russell left-side hose onto caliper so that banjo bends inward and is oriented
towards factory fork mounting point
(See Fig. 3) . Locate hose to fork with factory bracket around hose grommet.
Please study these instructions carefully before installing your new Brake Hose Kit. If you have any questions, please call
our Technical Hotline at: 1-800-416-8628, 7:00 am - 5:00 pm, Pacific Standard Time, Monday through Friday or
e-mail us at [email protected].
INSTALLATION INSTRUCTIONS
IMPORTANT NOTE: Do not allow the master cylinder to completely drain of brake fluid at any time during this process.
Also, use care when handling brake fluid, as it can quickly damage finished surfaces (paint, plating, etc.).
Fig. 1 Fig. 2 Fig. 3
IMPORTANT NOTE:
Proper installation is the responsibility of the installer. Improper installation will void warranty and may
result in poor performance and engine or vehicle damage.

©2006 Edelbrock Corporation
Rev. 7/06 - BC/mc
Catalog #R09783
Brochure #63-R09783
Page 2 of 2
Edelbrock Corporation, 2700 California Street, Torrance, CA 90503
Toll-Free Tech Line: 1-800-416-8628
Tech E-Mail: [email protected]
7. Route hoses behind forks and pull out between front fairing and fender. Install supplied cushion clamp over both
hoses so that mounting hole is to left and clamp/hoses are offset to front. Place horn bracket over hoses. Attach
hoses to bracket by inserting factory junction block bolt through cushion clamp and supplied nylon spacer and
threading into factory junction block mounting hole (See Fig. 4, shown installed on fork tree, top view) .
Leave bolt finger-tight. Re-install horn to bracket.
8. Route hoses behind front fairing and re-install horn bracket/dust shield assembly to fork tree.
9. Insert supplied double banjo bolt through both banjo hose ends, with right-side banjo on bottom. Thread banjo
bolt into master cylinder until finger-tight. Re-install master cylinder onto handlebar, orienting with mark made
earlier. Orient hoses so that banjos point forward over throttle cables, with left banjo to outside of right banjo
(See Fig. 5) . Tighten banjo bolt.
10. Use supplied cable tie to hold hoses to fork just above fork clamp. Route hoses underneath factory plastic hold-
down. Pull any remaining slack in hoses down through cushion clamp. Orient cushion clamp so hoses and clamp
do not contact horn and tighten clamp bolt
(See Fig. 6) . Plug in horn.
11. Check hose clearance throughout entire steering and suspension travel range.
12. Bleed the system and check for leaks while applying pressure.
Fig. 4 Fig. 5 Fig. 6