Wunderkind Custom BMR18T Original instructions

• www.wunderkind-custom.com ••• [e-mail] •
Installation manual and safety information
Handlebar Booster
BMW R18
From model year 2021

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 2 of 8
Caution
Important safety advice:
Working on motorcycles poses a safety risk. Some work may only be carried out by appropriately
qualified personnel. Faulty work can have serious consequences and may pose a threat to life and
health. Only undertake installation works if you are sufficiently qualified and have an official workshop
manual as well as all relevant service notifications available. Otherwise, we strongly recommend that
the installation is carried out or at least checked in a specialist workshop.
Any work in relation to the installation, removal and tightening torque of original parts should always be
carried out in compliance with the workshop manual.
All screws must be attached with thread-locking fluid. However, this should only be done after the
installation is complete.
It is your responsibility to check the product regularly and to determine if a service or replacement is
required.
Please bear in mind that some products are safety-relevant parts of your vehicle. After a fall or collision,
check the product and if there is the slightest indication of damage, you must completely replace it.
Some products require registration.
These products have been designed for a standard vehicle. ABM® Fahrzeugtechnik GmbH makes no
warranty or guarantee of any kind for any damages whatsoever arising out of the combination with
other component parts not tested by ABM, as a consequence of improper installation or inadequate
maintenance.
Brake fluid may damage painted surfaces and fairings. Use suitable means to protect all of the surfaces
against damage.
1
Preparation
Please read the entire safety information and installation manual carefully.
A motorcycle not securely positioned can fall over during the following work. Therefore, make sure
that the motorbike is positioned on solid, flat ground and is secured against falling over and rolling
away.
Keep children and pets away from the work area.
Protect removed parts from damage.
Please note when disassembling individual parts which screws are used to fasten them. Keep these
parts and screws and unless specified otherwise, reuse when assembling.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 3 of 8
2
Content
Make sure that the motorbike is securely positioned
Cover all parts in the handlebar area (tank, speedometer,
fender).
Drain the brake and clutch fluid according to the
manufacturer's specifications.
Remove both pumps and hydraulic lines.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 4 of 8
Unscrew the handlebar weights.
Dismantle the housing of the switch units on both sides,
loosen the fixing screws and unplug the plugs of the units.
Remove the switch units.
Remove the two screws under the top yoke, pull the
cable harness out of the handlebar and remove the
handlebar with the risers.
Remove the original screws and bushings.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 5 of 8
Use the bushings provided for installation.
Attach the booster risers as follows:
From below, push the two screws provided together
with the safety washers, washers as well as large
diameter washers and bushings into the top yoke.
From above, insert two further bushings into the top
yoke and screw the riser onto the thread (see
drawing).
Caution: The narrow side of the risers must be
aligned towards the driver.
Insert the handlebar (0429 or 0410) into the risers and
fasten lightly.
Next, fasten the risers from below using the two
screws (M10).
Tightening torque 48 Nm.
Remove the handlebar again and check the screw
length.
Make sure that the screw does not end in the clamp
area of the handlebar.
Make sure that the screw ends no more than 1.5mm
inside the riser.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 6 of 8
Caution:
During installation, make sure that there is a gap on
both sides between top and bottom and no surface
touches anything.
Insert the handlebar back into the risers, adjust as
desired and fasten.
Tightening torque 25 Nm
Push the reduction sleeves onto the handlebar on the
left and right side.
Attach the handlebar extensions provided on both
sides and fasten.
Caution: It is not possible to attach another
handlebar end to the handlebar.
Push the switch units onto the handlebar until the
handlebar extensions protrude approx. 2-4mm.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 7 of 8
The final assembly of the operating elements requires
the drilling of holes for the centring pins. To do this,
align the operating elements and mark the positions
for the centring pins (push onto the pins using grease).
Now, centre-punch the marked position and drill a
hole (diameter and depth are based on the centring
pin).
Reconnect the plug connectors of the handlebar
switches.
Assemble the handlebar switches.
Align the brake and clutch pump with the reduction
sleeves and attach.
Attach the brake and clutch lines provided to the
pumps and manifolds.
Tightening torque: 21 Nm
Caution: Always use new sealing rings.
To ensure a twist-free installation, the cable
connections can be aligned once at the fitting.
Check with static brake that the brake lever can be pulled
up to the handle and under no circumstances touches
other parts.
After installing the Stahlflex lines and pumps, the
complete system must be drained according to the
manufacturer's installation instructions.
After the final assembly, check the freedom of
movement of all brakelines and cables and fasten
them only to such an extent that they are not bent, do
not chafe and are tension-free in maximum steering
angle and over the entire spring travel.

Installation manual
• Revision: 00 • 30/04/2021 © ABM Fahrzeugtechnik GmbH Page 8 of 8
Make sure that all operating elements present on the handlebar are adequately positioned,
even in maximum steering angle. The brake and clutch cylinders must be in an adequate
operating position.
Pay attention to the freedom of movement of the handlebar, its mounted parts and adequate
steering angle to each side. The handlebar must be able to be moved easily from side to side.
Check the free play of the throttle cable: In maximum steering angle to both sides and with the
engine running, the motor speed must not change.
After completing the work, check the firm fit, function and tightness of all components and
screws. Make sure that there is sufficient brake fluid in the reservoir. Also check the front
wheel's freewheel and the functionality of the brake system. Further, the function of the clutch,
the throttle grip, the electric system and the anti-theft devices must be checked.
Afterwards, a test drive must be carried out! After completion of the test drive, all screw
connections must be re-checked for firm fit, tightness and all movable parts for adequate free
travel. Re-test the front wheel's freewheel and check the brake system for overheating. Check
the brake fluid level in the reservoir for significant changes.
Fasten all screws with thread-locking fluid (medium
strength) and the preset tightening torque.
Check the proper function of the electrical system.
4
Final check