52.00 DISC MOUNTING OFFSET SET WITH LOAD SPREADING SPACER REF M8x1.25 CAP HEAD BOLT MOUNTING DETAILS LUG LUG 1 LUG

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2 HOME T.O.C. SEARCH PRINT Supermoto 165 INTRODUCTION AP Racing has developed an advanced Supermoto Home braking system. This new system is available as a kit. Page CP4680 BRAKE CALIPER DIS CP 5 DI SC O UT S ID ATH E WA DI SPACER-VAROIUS YR AM AD THICKNESSAVAILABLE IUS ET 1 ER 61. TO SUIT RANGE OF OFFSETS 5 EXISTING MOUNTING LUG SELECTION OF MOUNTING BOSSES TO SUIT DIFFERENT FORKS MOUNTING DETAILS CP4680-3S0 CALIPER TO SUIT YAMAHA APPLICATIONS CP CP4860D27 Variable Ratio Master Cylinder. Brake Pad FEATURES: - Unique pull type design. - Single chamber Bore. - Incremental ratio adjustment. - Adjustable lever reach position. - Weight = 320g TECHNICAL SPECS: - Friction Material = Sintered. - Pad Thickness = 7.4mm. - Pad area = 19.4cm². - Swept Depth = 27.0mm. - Part Number = CP4680D27-SRR NEXT PAGE PAGE BACK CP4680-3S0 CALIPER TO SUIT SUZUKI APPLICATIONS LUG CP4680-3S0 CALIPER TO SUIT PRE-2004 HONDA APPLICATIONS SUPERMOTO BRAKE KIT APPLICATION GUIDE Make. Model. Honda CRF (1.61 ) 76.3 (3.00 ) LUG LUG 1 Kawasaki Suzuki Yamaha KX 250 DRZ 400 RMZ 450 WRF 450 Year All All 04 All Kit Part No. Disc Assy Part No. CP CP CP CP CP CP (0) PREVIOUS VIEW 7 LUG 2 LUG 2 LUG 2 LUG CP4680-9S0 CALIPER TO SUIT 2004-ON, HONDA APPLICATIONS - Disc Diameter = 320.0mm - Disc Thickness = 6.0mm - Swept Depth = 27.0mm - Disc Face Type = Crossed Drilled - Weight = 1.56Kg THREADED MOUNTING BOSS REF M8x1.25 CAP HEAD BOLT TECHNICAL SPECS: BLEEDSCREW TIGHTENING TORQUE TO BE 5.5Nm (4lbs?ft) 36.0mm x cm² Brake - Piston Area 320.0mm Calipers - Disc Diameter - Disc Thickness 6mm - Weight (Less Pads) 640g - Hydraulic Threads M10 x For mounting details see opposite. - Seal Repair Kit CP4518-EH STAINLESS STEEL DISC. INSTALLATION DRAWING DISC MOUNTING OFFSET SET WITH LOAD SPREADING SPACER Master Cylinders - 4 Piston. - Unique patented lug mounting system Carbon/ - Differential bores, for extended pad life. Carbon - Aluminium alloy body. - High temperature seals. Clutches - Hard anodised surface treatment. - Lightweight. Sidecar - R Clip pad retainer. Product Range PART NUMBERS. - CP4680-3S0 - CP4680-9S0 (Honda 2004 on) Classic Spares SPECIFICATIONS. Range - Piston Size 31.6mm x Brake Pads Brake Discs Brake Kits The kit comprises a 4 piston differential bore caliper with a unique patented direct mounting system. High friction sintered brake pads, a Ø320.0mm Stainless Steel disc and a variable ratio master cylinder. This state of the art brake kit offers unrivalled stopping power with a uniquely versatile mounting system. The AP Racing Supermoto brake kit was used by Danni Muller and the WRE Yamaha Team to win every round of the recent UK Championship.

3 166 INTRODUCTION Developed from our unrivalled experience in Superbike Racing, these lightweight brake conversion kits are compact in design attractive in appearance and high in performance. The individual applications enable the complete conversion to be a direct bolt on replacement for the original equipment brake system. All kits are supplied with full and comprehensive fi tting instructions. Full competition kits are also available, please contact AP Racing Department for further details. *Please note:* USA or Canada customers should contact - GP Tech L.L.C. Tel: AP RACING MOTORCYCLE BRAKE KITS HAVE: - Increased Stopping Power. Performance discs and stiffer calipers mean more power. - Reduced Fade. Greater tolerance to heat build up means consistent stops. - Racing Pedigree. Built and designed with the same care and by the same technicians as our racing brakes. Brake Kits PERFORMANCE KIT COMPONENTS CALIPERS:- - CP7853, is a lightweight 4 piston, two piece radial caliper. Where applicable CP7853 will be the main caliper used in all new conversion kits. DISCS:- All discs used in the performance kits are manufactured from a special high quality Stainless Steel and machined to the highest accuracy. PADS:- Kits are supplied with a set of high performance pads for track days. Pads for competition use are also available. BRAKE FLUID:- Each kit is supplied with a bottle of Formula DOT 5.1 performance fl uid. Make Model Year Honda CBR1000RR 2004 on. Kawasaki ZX10R 2004 on. Suzuki Yamaha INSTALLATION Installation of the Brake kit is relatively simple, however because it will be necessary to obtain brake lines, AP Racing strongly recommends that the work is carried out by a competent dealership or performance shop. BRAKE LINES. AP Racing recommends Goodridge 3 steel braided brake hose. Two brake lines should be used. The length of each hose must be established with the front wheel clear of the ground to ensure that the hose end fi ttings are not loaded at any time. Goodridge can supply the banjo end fi ttings; banjo bolts and copper gaskets together with the necessary hose retaining clips. The inlet thread in the AP Racing caliper is metric 10x1. Banjo bolts should be tightened to a torque of 25NM NOTES GSXR1000K3 & K on. GSXR1000K5 & K / 6 GSXR750 GSXR600 YZFR1 YZFR on on Kit Part No. PART NUMBERS:- CP CP CP CP CP CP Brake Caliper. CP7853

4 Brake Discs INTRODUCTION AP Racing Disc and Bell assemblies are lightweight in design and are Ø320mm diameter. All the discs listed in the table below are 6mm thick and have been designed for use exclusively with our 6 and 4 piston brake calipers. The special high grade stainless steel used in AP Racing brake discs combine high performance with thermal stability. N.B. AP Racing discs are not OE Replacements. In most cases they are not suitable to be used with the original OE Brake Calipers. All new brake discs must be carefully run-in (see below) BEDDING PROCEDURE AP Racing performance discs are manufactured in accordance with ISO9001. Careful running in of new discs is critical for optimum performance and to maximize disc life. - Brake gently at fi rst, gradually increasing the severity of stops for the fi rst 200 / 250 miles of road use until the disc surface attains an even colour. - In the case of racing use, light braking for 10 laps (30 miles) is recommended - Do not run the brake against the engine. Failure to comply will result in high spots, warped discs and brake judder. AP Racing, their Distributors and Dealers cannot be held responsible for incorrectly bedded discs. Discs stripped from the mounting bell or assemblies modified or incorrectly fitted. - The braking faces must be examined regularly to ensure they are free from cracking or surface crazing. Any disc exhibiting cracks or crazing must not be used. Discs must be replaced after 12 months use. If you require any further information please contact our department. DISC HANDING AP Racing discs with a drilled braking face pattern are Non-Handed. EXPLANATION OF DISC DIMENSIONS All discs are nominal Ø320.0mm and are cross-drilled x 6 mm thickness. Other disc dimensions are in table below. L = No. of Holes. T = Hole Ø M = P.C.D. C = Offset. Ø / 5.85 Ø B 6.00 C 167 BRAKE DISC APPLICATIONS. Note: Contact AP Racing Technical Department for further information on the disc and bells listed below. Not replacements for OEM Discs BRAKE MOUNTING BELL DIMENSIONS. Available mounting bell options to suit -302 rotor. Contact AP Racing for further information. Application. Mounting Dimensions. Dim n No. Dia. M L T P.C.D. Dim n B I/Dia. Dim n C Offset. Mounting Bell Part No. Disc Assembly Part No. Aprilla. RSV (including Mille) & Falcon Ducati. 748 / 916 / 996 / Sta / 996 Race Honda. Fireblade 94 / Fireblade C[ CBR1000RR / SP1 / SP2 Kawasaki ZX10R ZX7 / 9R - 97 (Road) Race Suzuki. GSXR600 / On. GSXR600 & 700. GSXR1000, 02 on. GSXR Race / Yamaha. R6 / R1-98 on / YZF YZF750 / R1 Race Important Note: All of the discs above use -302 Stainless Steel Rotor. Mounting Bell Part Number ID. P.C.D. Hole Ø. Hole No. Offset neg neg neg neg Thickness 6.0

5 168 Brake Pads BRAKE PADS The table below provides information and guidance on the suitability of friction materials available for brake pad profi les from within the AP Racing range. See Brake Pad profi les listed below. Pad Part Number. Material. Average Friction Mµ. Thickness. Caliper Family. Application. Typical Use. CP2195D38-APH420 SBS Organic 0.39 Solo Machines Front & Rear Road CP2195D38-RQ3 SBS Organic mm CP2195 / CP2696 CP2195D38-M1144 Mintex Organic 0.32 Sidecars Race CP2195D38-M1144 Mintex Organic 0.30 CP H4/1 CP M2 Carbon/Carbon N/A 8.0mm CP4488 Moto GP1 Race CP4226D27-APH420 CP4226D27-RQ3 SBS Organic mm Road / Race CP4226D27-CRR 0.59 CP4226 / CP4227 Solo Rear Brake Race CP4226D27-RX Sintered Carbon Lorraine mm Road / Race CP4466D22-RQ3 SBS Organic 0.41 Road CP4466D22-DS3000P Ferodo Organic 0.45 CP4466D22-SRR SBS Sintered mm CP4466 Solo Machines Front Road / Race CP4466D22-XR Ferodo Sintered TBA Race CP4484D34-DS3000P Ferodo Organic 0.45 Road / Race CP4484D34-SF SBS Sintered 0.50 Road 8.0 CP4484 / CP3369 Solo Machines Front CP4484D34-RQ3 SBS Organic 0.41 Road CP4484D34-RQ3 SBS Organic 0.41 CP4485D27-RQ3 CP4485D34-RQ3 SBS Organic CP4485 Nicole Racing Only Road CP4488D27-SRR SBS Sintered 0.55 Road / Race CP4488D27-CRR SBS Organic 0.55 Race 9.5mm CP4488 / CP7853 Superbike / Formula Extreme CP4488D27-DS3000P Ferodo Organic 0.45 Road / Race CP4488D27-XR Ferodo Sintered TBA Race CP4680D27-SRR SBS Sintered 0.55 Supermoto Sintered 7.4mm CP4680 CP4680D27-CRR SBS Organic 0.59 Supermoto Carbon Ceramic Race CP5569D34-APH420 SBS Organic mm CP5569 Nicole Racing Only Road CP6688D29-SRR SBS Sintered 0.55 CP6688D29-CRR SBS Organic mm CP6688 Superbike Race CPFO105D44-APH420 SBS Organic mm Norton Lockheed Norton Commando Road NOTE: PAD PROFILE DRAWINGS ARE NOT TO SCALE. CP2195D38 - Pad Thickness = 10.5mm (0.40 ) - Pad Depth = 38.4mm (1.51 ) - Pad Area = 22.4cm² (3.47in²) 59.3 (2.34 ) CP4226D27 - Pad Thickness = 7.0mm (0.27 ) - Pad Depth = 26.84mm (1.05 ) - Pad Area = 9.4cm² (1.45in²) 39.7 (1.56 ) CP4466D22 - Pad Thickness = 9.0mm (0.35 ) - Pad Depth = 22.0mm (0.86 ) - Pad Area = 19.83cm² (3.07in²) (3.95 ) 51.1 (2.02 ) 39.7 (1.56 ) (1.40 ) CP4484D34 - Pad Thickness = 8.0mm (0.31 ) - Pad Depth = 34.0mm (1.34 ) - Pad Area = 24.14cm² (3.74in²) (3.00 ) CP4488D27 - Pad Thickness = 9.5mm (0.37 ) - Pad Depth = 27.0mm (1.06 ) - Pad Area = 18.55cm² (2.87in²) 76.3 (3.00 ) CP4680D27 - Pad Thickness = 7.4mm (0.29 ) - Pad Depth = 27.0mm (1.06 ) - Pad Area = 18.55cm² (2.87in²) 76.3 (3.00 ) (1.81 ) (1.61 ) (1.61 ) CP6688D29 - Pad Thickness = 10.0mm (0.39 ) - Pad Depth = 28.5mm (1.12 ) - Pad Area = 11.09cm² (1.71.in²) 41.0 (1.61 ) 28.5 (1.12 )

6 Master Cylinders INTRODUCTION The range of AP Racing master cylinders are patented, worldwide state of the art products that are a major advance in brake technology offering the ability to precisely set the braking performance of any motorcycle under all conditions. CP4325, CP4225 & CP4125 cylinders have a unique radial pull type design with variable lever ratio and span adjustment which can cater for all hand spans. All AP Racing master cylinders are merticulously manufactured and rigorously tested for the peace of mind of the rider. MASTER CYLINDER RANGE CP4325 The DB Dual bore, pull type cylinder, a major break through in motorcycle safety. AP Racing have developed a twin circuit front brake master cylinder for effective braking with a partially failed system. The compact design weighs only 450grams. This twin circuit master cylinder is suitable for Grand Prix and Superbike Machines & selected Road Bikes. Two x push on inlet adaptors, Two x M10 x 1.0mm outlet ports, Use with remote fl uid reservoirs. Note - Fluid Reservoirs not included. CP4225 A thumb operated rear master cylinder, pull type, single chamber in design. Used in conjunction with CP4227 dual feed caliper to assist in the corner control of GP and Superbike motorcycles, while still allowing the use of a foot operated rear master cylinder. Use with remote fl uid reservoir (not supplied). CP4125 This unique design of pull type handlebar master cylinder provides the user with the ability to adjust the ratio and the lever position as required. The single chamber confi guration allows the compact design to weigh only 320grams, and is now non handed to allow it to be used as a clutch master cylinder. This master cylinder is used by top GP and Superbike teams. Use with remote fl uid reservoir (not supplied) CP3125 The original adjustable ratio master cylinder used by GP and Superbike teams in the 80 s. Can be used to upgrade any brake system. Available for single or twin brakes with a left hand version for clutch actuation. Available with integral reservoir only. CP6125 New design pulltype, single chamber master cylinder with two fi xed ratio positions. Lower price alternative to CP4125 suitable for single or twin brake systems. CP3756 This uniquely developed single chamber, pull type rear master cylinder, has been designed for use on all solo motorcycle applications. The pull type confi guration allows an exceptionally compact design for ease of installation. Weight 100grams. CP2215 Due to demand CP Classic master cylinder has been added to the range. The new assembly is based on the original CP cylinder, but using latest seal technology. CP2232 Due to demand CP Classic rear master cylinder has been added to the range. The new assembly is based on the original CP cylinder, but using latest seal technology. RECONDITIONING CP4325, CP4225. User reconditioning is limited to replacing lever assemblies. However AP Racing offer a reconditioning service for seal and piston replacement where the use of specialist test equipment is necessary to set up the master cylinder. CP6125, CP4125, CP3125, CP2215 & CP2232 User servicing of these master cylinders is possible and seal repair kits are available. Obsolete Master Cylinders Seal repair kits are available for master cylinders which are no longer in the range. IMPORTANT NOTE IF ANY IMPACT IS SUSTAINED ON THE LEVER OR CYLINDER BODY, THE COMPLETE MASTER CYLINDER ASSEMBLY MUST BE SENT BACK TO AP RACING FOR EXAMINATION OR BE REPLACED. NOTES 169

7 170 CP4325 DB Dual Bore, Adjustable Ratio Master Cylinders CP4225 Thumb Brake Rear Master Cylinder. - Dual Bore / Dual Circuit. - Twin chamber cylinder. - Unique pull type design. - Adjustable lever reach position. 4 set positions of adjustment. - Incremental ratio adjustments. Ratio is :1 - Use with remote fl uid reservoirs. (reservoirs not included.) - Grand Prix Machines. - Superbikes. - Selected Road Bikes. ASSEMBLY PART NUMBER. - CP Weight 440g - Effective bore size 14mm -19mm. - Actual bore size 16.0mm (0.63 ) - Stroke 8.5mm (0.31 ) - Hydraulic Connections - Outlet thread 2 x M10 x Bleed Screw Tightening Torque 5.5Nm (4lbs/ft) RATIO ADJUSTMENTS GUIDE. This variable ratio master cylinder has a knulled wheel to adjust the ratio. This adjuster is rotated to increase or decrease the lever ratio. TECHNICAL SPECIFICATIONS AND NOTES. AP Racing has developed a dual bore pull type front brake master cylinder based on our world patented variable lever ratio design. The master cylinder uses a separate chamber for each front caliper and each chamber has its own fl uid reservoir. The two chambers are actuated through a balance device, which ensures equal line pressure to both calipers. In the event of loss of pressure in one caliper fl uid pressure can be generated in the remaining caliper offering effective safe braking. The variable ratio lever together with span adjustments means that the master cylinder can be tailored to suit individual requirements. INSTALLATION & BLEED. Each circuit should be provided with a reservoir with suffi cient capacity to suit the calipers fi tted. It is recommended that the cylinder be adjusted to its lowest ratio to bleed the brake system. This gives maximum fl uid displacement and helps to purge the system. Once the system is bled of all air, the ratio and lever span can be adjusted to suit. Master cylinders are supplied with the wheel adjuster set at position 0 (i.e. with the fulcrum point at end of guide slot in lever, nearest to end of the handlebars, as drawn) at this setting piston travel is at its maximum. Lever travel will usually increase slightly for dynamic applications compared with the static setting. It is recommended that lever feel is set slightly hard for the initial test, until this effect has been evaluated. SERVICING. To maintain peak effi ciency periodically apply a thin smear of Duckhams Q5795 Moly-Bentone grease (or Equivalent) to the sliding bearing of the lever in the body. This master cylinder is a complex assembly containing no customer serviceable internal components. It is recommended that the master cylinder be returned to AP Racing as required for servicing, or for examination in the vent of any damage. If any impact is sustained on the lever causing a high pressure input to the brake system, the whole system should be replaced. - This state of the art adjustable ratio rear thumb brake master cylinder when used inconjunction with the CP4227 dual feed caliper was designed to assist in the corner control of the motorcycle, while still allowing the use of a foot operated rear master cylinder. - Use with remote fl uid reservoir. (not supplied) - Effective bore size ranging from 13 to 15mm. - Incremental ratio adjustment. Ratio is :1 - Adjustable lever reach position. - Grand Prix machines - Superbikes. ASSEMBLY PART NUMBER. - CP Weight 310g - Effective bore size 13mm -15.mm - Actual bore size 15.8mm (0.62 ) - Hydraulic Connections - Outlet thread M10 x Bleed Screw Tightening Torque 5.5Nm (4lbs/ft) RATIO ADJUSTMENTS GUIDE. This variable ratio master cylinder has a knulled wheel to adjust the ratio. This adjuster is rotated to increase or decrease the lever ratio. TECHNICAL SPECIFICATIONS AND NOTES. -Master Cylinder will be supplied with the wheel adjuster set at position 0 ( i.e. with the fulcrum point at end of guide slot in lever, nearest to end of the handlebars, as drawn) at this setting piston travel is at its maximum, which will give best conditions for bleeding the brake system. Typical working stroke is shown as a guide only, working stroke should be set to riders preference. After initial setting only small adjustments, typically ±1 turn should be necessary to suit differing conditions. - Lever travel will usually increase slightly in dynamic applications over static settings due to disc runout etc. it is therefore advisable to set lever feel on the hard side for initial test. - Master Cylinder will be supplied with the lever reach set at the nominal position as drawn. To obtain a longer reach the adjuster should be turned anti-clockwise using a 3mm A/F hexagon socket key wrench to suit riders preference. Conversely the adjustments can be made in ¼ turn increments, but should not be set between detents positions. The correct lever reach should be established prior to any adjustment to the lever ratio using the wheel adjuster. - Outlet fi tting is not supplied with assembly as standard, but Tecalamit or Aeroquip are available on request. - To remove lever sub-assembly, take the Master Cylinder off the handlebar, then set wheel adjuster in position 0. Turn lever reach adjuster clockwise until disconnected from the end of pullrod. The lever sub assembly will then slide out from the retaining fl anges. To replace lever sub-assembly reverse the above procedure. - Important: If any impact is sustained on the lever causing a high pressure input to brake system, whole system should be replaced.

8 Master Cylinders CP4125 Adjustable Ratio Master Cylinder CP3125 Original Adjustable Ratio Master Cylinder Single chamber confi guration. - This unique design of pull type handlebar master cylinder provides the user with the ability to adjust the lever ratio and the lever position in increments as required. - Reverse for use as clutch master cylinder. - Use with remote fl uid reservoir. (Not supplied) - Incremental ratio adjustments. Ratio is :1 - Grand Prix machines - Superbikes. - Road. ASSEMBLY PART NUMBER. - CP (17mm to 20mm effective bore) - CP (12mm to 15mm effective bore) - Weight 304g - Effective bore size 12mm -20mm. - Actual bore size - CP mm (0.86 ) - CP mm (0.62 ) - Hydraulic Connections - Outlet thread M10 x Bleed Screw Tightening Torque 5.5Nm (4lbs/ft) - Repair Kit - CP CP RK - CP CP RK RATIO ADJUSTMENTS GUIDE. This variable ratio master cylinder has a knulled wheel to adjust the ratio. This adjuster is rotated to increase or decrease the lever ratio. TECHNICAL SPECIFICATIONS & NOTES. - Master Cylinder will be supplied with the wheel adjuster set at position 0 ( i.e. with the fulcrum point at end of guide slot in lever, nearest to end of the handlebars, as drawn) at this setting piston travel is at its maximum, which will give best conditions for bleeding the brake system. Typical working stroke is shown as a guide only, working stroke should be set to riders preference. After initial setting only small adjustments, typically ±1 turn should be necessary to suit differing conditions. The ratio adjuster wheel has a detent mechanism allowing it to be moved ¼ turn per click. No locking of the mechanism is required. Lever travel will usually increase slightly in dynamic applications over static settings due to disc run-out etc. it is therefore advisable to set lever feel on the hard side for initial test. - Master Cylinder will be supplied with the lever reach set at the nominal position as drawn. To obtain a longer reach the adjuster should be turned anti-clockwise using the reach adjuster wheel to suit riders preference. Conversely the adjuster can be turned clockwise to give a shorter reach. Adjustments should be made in ¼ turn increments, but should not be set between detents positions. The correct lever reach should be established prior to any adjustment to the lever ratio using the wheel adjuster. - Outlet fi tting is not supplied with assembly as standard, but Tecalamit or Aeroquip are available on request. - To remove lever sub-assembly, take the Master Cylinder off the handlebar, then set wheel adjuster in position 0. Knock out spring and remove the lever reach adjuster wheel. Turn the exposed pull rod clockwise using the 1mm slot in it s end until the lever assembly is disconnected from the pull rod lever sub-assembly will then slide out from the retaining fl anges. To replace lever sub-assembly reverse the above procedure. - Important: If any impact is sustained on lever causing a high pressure input to brake system, whole system should be replaced. - The original adjustable ratio brake master cylinder can be used to up grade any brake system. - Left hand version available for clutch actuation. - Supplied with integral fl uid reservoir. - Incremental ratio adjustments :1 - Historic Grand Prix & Superbike machines - Road. ASSEMBLY PART NUMBER. - CP R/H (16mm to 19mm effective bore) - CP R/H (12mm to 16mm effective bore) - CP L/H (12mm to 16mm effective bore) - Weight 475g - Effective bore size 12mm -19mm. - Actual bore size - - CP mm (0.74 ) - CP & mm (0.62 ) - Hydraulic Connections - Outlet thread M10 x Bleed Screw Tightening Torque 5.5Nm (4lbs/ft) - Repair Kit - CP CP3125-2RK - CP & -5 CP3125-4RK RATIO ADJUSTMENTS GUIDE. This variable ratio master cylinders has a screw to adjust the ratio. This adjuster is moved to and away from the handlebar with the effects detailed in the table below. GUIDE TO ADJUSTMENT Screw Adjuster Braking Lever Travel Lever Feel In - Clockwise Decreased Decreased Harder Out - Anti-Clockwise Increased Increased Softer TECHNICAL SPECIFICATIONS & NOTES. - Master cylinder will be supplied with the screw adjuster set at position 0 (i.e. with the adjuster fl ush with locknut as drawn) at this setting piston travel is at its maximum, which will give best conditions for bleeding the brake system. Typical working stroke is shown as a guide (see table opposite) only working stroke should be set to riders preference. After initial setting only small adjustments, typically ±½ turn should be necessary to suit differing conditions. - Lever travel will usually increase slightly in dynamic applications over static settings due to disc runout etc. it is therefore advisable to set lever feel on the hard side for initial test. - Important: If any impact is sustained on lever causing a high pressure input to brake system, the whole system should be either replaced or set back to AP Racing for examination.

9 172 CP Master Cylinder Master Cylinders CP Pull Type Rear Master Cylinder The new CP master cylinder is based on CP4125 design, featuring two fi xed ratio positions. - Single chamber confi guration. - Two fi xed ratio positions - Ratio are 10:1 and 7:1 - Adjustable lever position. - Reverse for use as clutch master cylinder. - Use with remote fl uid reservoir. (not supplied) - Grand Prix machines - Superbikes. - Road. - Weight 290g - Effective bore size 17mm and 20mm. - Actual bore size 22.0mm (0.86 ) - Hydraulic Connections - Outlet thread M10 x Bleed Screw Tightening Torque 5.5Nm (4lbs/ft) - Repair Kit CP RK CP Classic Master Cylinder - Pull type confi guration. - allows for a compact installation. - Single chamber, single seal. - Aluminium alloy body. - Manufactured from high quality castings. - All Solo machines - Weight 100g - Effective bore size 14.0mm. - Actual bore size mm (0.625 ) - Stroke 16.2mm (0.638 ) - Hydraulic Connections - Push-on inlet 7.9mm (5/16 ) inside Ø hose - Outlet thread M10 x 1.0 RECONDITIONING / SERVICING. For reconditioning / servicing the cylinder needs to be returned to AP Racing. CP Classic Rear Master Cylinder Re-introduced to satisfy demand generated by restoration and classic racing series. - The original Classic master cylinder. - Aluminium alloy body and cap. - Suitable for single and twin disc applications. - Integral fl uid reservoir. - manufactured from high quality castings. - Replaces CP Classic Racing and Road s. - Weight 520g. - Actual bore size mm (0.625 ) - Stroke 16.0mm (0.638 ) - Hydraulic Connections - Outlet thread 3/8 x 24UNF - Fluid Reservoir Capacity 50cc When re-fi lling reservoir reform internal bellows as fl at as possible prior to re-fi tting. - Repair Kit CP5678-1RK - Lever Part No CP Re-introduced to satisfy demand generated by restoration and classic racing series. - The original Classic rear master cylinder. - Aluminium alloy body. - manufactured from high quality castings. - Integral fl uid reservoir. - Replaces CP Classic Racing and Road s. - Weight 300g. - Actual bore size mm (0.625 ) - Stroke 11.8mm (0.46 ) - Hydraulic Connections - Outlet thread 3/8 x 24UNF - Fluid Capacity 35cc - Repair Kit CP5678-1RK

10 AP Racing is the world leader in design and manufacture of Carbon/Carbon Clutches winning many Car GP and many Championships worldwide. The same technology used in these successes are used in clutches within the range. Carbon Clutch AP Racings Ø115mm Carbon/Carbon Clutches offer many advantages. - Low weight. - Low Inertia. - High temperature / abuse resistance (repeated starts. - Greatly extended life. - Over-run Centre. (Slipper) Carbon/Carbon clutches are engineered for each application, and AP Racing offers a complete service from design to installation. All AP Racing Carbon/Carbon Clutches incorporate an overrun device (slipper type) within the clutch hub. For more information regarding carbon/carbon clutches please see pages 94 to 98 or contact AP Racing motorcycle section. FEATURES AND TYPICAL SPECIFICATIONS GUIDE TO A Ø115MM MOTORCYCLE CARBON/CARBON CLUTCH - 10 Bolt. - Pull Type Confi guration. - increased effi ciency in terms of clamp and release loads. - Over-run (slipper) Clutch. - prevents rear wheel locking when down changing. - Heavy duty. - Long Life and Durable. - Factory Reconditioning Service Available. TYPICAL TECHNICAL SPECIFICATIONS - Torque Capacity. 339Nm (294lbs/ft) - Release Loads. - Max Peak Worn 145daN - At Travel 95daN - Wear In Between. P/Plate Changes 0.40mm - Total Allowable Carbon. Stack Wear. 3.0mm - Weight. 1.6kg (This will vary upon application) - Complete Assy Inertia kgm² - Driven Plates and Hub Inertia kgm² 173 TYPICAL INSTALLATION DRAWING The installation drawing below depicts a typical Ø115mm Carbon/Carbon Clutch. Dimensions and instructions are a guide only. A 10 MOUNTING STUDS/NUTS (M4 x 0.70 EQUISPACED ON A Ø P.C. CARBON / CARBON STACK HEIGHT NUTS TO BE TIGHTENED IN A DIAMETRICALLY OPPOSITE SEQUENCE. HALF A TURN AT A TIME. RECOMMENDED TIGHTENING TORQUE 4.5Nm RELEASE TRAVEL TO BE 2.5MM Ø MAX Ø MAX Ø MAX AXAIL FLOAT RELEASE TRAVEL A B CLUTCH S.U.H WHEN WORN PLATES TO BE INSTALLED WITH IDENTIFICATION NOTCHES IN THE ORDER SHOWN. (NOTCHES TOWARDS COVER). CLUTCH S.U.H WHEN NEW FLYWHEEL FACE CHAMFERED SIDE AGAINST FLYWHEEL FACE

11 174 Sidecar Braking Equipment INTRODUCTION The parts information detailed below is braking equipment for LCR or similar World Championship Sidecar outfi ts. These components are as used by Steve Webster, 10 times World Champion and many more competitors. For further information please contact AP Racing motorcycle section. CP7030-2S0 4 Piston Brake Caliper CP3345-2S4 4 Piston Brake Caliper CP2577-3E0 2 Piston Brake Caliper - Lug mount. - Operates on solid disc. - Non Handed. - One piece aluminium alloy body. - Hard anodised surface treatment. - Radial mount. - To suit Ø278.0mm x 17.0/16.0mm disc. - Two piece aluminium alloy body, CNC machined from billet. - Lightweight. - Differential bores, to control pad taper. - Aluminium pistons. - High temperature seals. - Hard anodised surface treatment. - Stainless steel bridge pipe, pad abutments & wear plates fi tted. TECHNICAL SPECIFICATION - Piston Diameter 34.9mm x mm x 2 - Disc Diameter 278.0mm - Disc Thickness - Max 17.0mm - Min 16.0mm - Weight (Less Pads) 1.5Kg - Hydraulic Threads M10 x Mounting Radial - centres 130.0mm - offset 40.0mm - hole Ø 10.2mm - PL Dimension 50.3mm - Seal Repair Kit CP4518-GK - Bleed Screw Tightening Torque 17Nm (12.5lbs/ft) PAD FAMILY - CP3345D38 - Pad Area = 38.7cm² - Pad Depth = 38.0mm - Pad Thickness = 16.0mm SPARE PARTS. - Pistons - Ø34.9mm CP Ø41.3mm CP Wear Plates CP x 4 - Bleed Screw CP Fluid Pipe CP piece radial mount - Aluminium alloy body. - Differential bores- minimises pad taper. - H/Piece pad retainer. - Stainless steel bridge pipe, pad abutments & wear plates fi tted. - Hard anodised surface treatment. TECHNICAL SPECIFICATIONS. - Piston Diameter 38.1mm x mm x 2 - Disc Diameter 280mm - Disc Thickness mm - Mounting Radial - Centres 130.0mm - Offset 40.6mm - PL Dimension 50.5mm - Mounting Holes Ø 9.6mm - Hydraulic Threads 3/8 x 24UNF - Seal Repair Kit CP4518-JK - Bleed Screw Tightening Torque 17Nm (12.5lbs/ft) PAD FAMILY - CP2340D43. - Pad Area = 40.4cm² - Pad Depth = 43.1mm - Pad Thickness = 15.9mm SPARE PARTS. - Pistons - Ø38.1 CP Ø41.3 CP Pad Retainer H/Piece - Retainer P/No CP Retainer Bolt CP Wear Plates CP Bleed Screw CP Fluid Pipe CP Piston Diameter 41.3mm x 2 - Disc Diameter Max Min 254.0mm - Disc Thickness 9.7mm - Mounting Lug - Centres x offset 89.0mm x 24.6mm - PL Dimension 47.0mm - Mounting Holes Ø9.6mm -Hydraulic Threads 3/8 x 24UNF - Seal Repair Kit CP4518-K - Bleed Screw Tightening Torque 17Nm (12.5lbs/ft) PAD FAMILY - CP2399D43. - Pad Area = 40.4cm² - Pad Depth = 43.1mm - Pad Thickness = 15.9mm SPARE PARTS. - Pistons CP Pad Retainer R/Clip CP Bleed Screw CP CP2623 Compact Master Cylinder This compact cylinder is for all brake applications especially where space is restricted. - Weight 300g - Full Stroke 25.4mm - Travel to cut-off 0.27 to Hydraulic Thread - Outlet 3/8 x 24UNF - Inlet 7/16 x 20UNF - Push Rods M8 x 1.25 or 5/16 UNF - Push Rod Lengths 115mm or 160mm - Bore Sizes Available - 14mm - CP mm - CP CP mm CP CP CP CP CP CP CP Note: See Page 68, for full part numbers.

12 Classic Spare Parts SPARES FOR CLASSIC EQUIPMENT. N.B. Assemblies not available. Listed spares only. Available part numbers identifi ed by bold and underlined text. 175 CP & CP Brake Master Cylinders CP Bore Size (5/8 ). - Identifi ed by single groove. - Repair Kit CP RK - Lever CP CP Bore Size Identifi ed by single groove - Repair Kit CP3179RK - Lever - CP CP & CP Brake Master Cylinders CP Bore Size Identifi ed by two grooves - Repair Kit CP RK - Lever CP CP Left Hand Clutch Master Cylinders - Bore Size (5/8 ). - Repair Kit CP RK - Lever CP CP Bore Size Identifi ed by two grooves. - Repair Kit CP3180RK - Lever - CP TRIUMPH TRIDENT CLUTCH - Clutch Plate (HB3079) - Diaphragm Spring 75303/16 - (Parts also suitable for BSA Rocket 3) HB /16 NOTES

13 176 Customer Notes