Instruction Sheet For Tool No. 738
Contents
1. Performing brake fluid Flush FIG 2 1 Hook up JIMS injector tool so it is pulling brake fluid from brake caliper bleeder screw and injecting fluid into the bottle Install 15 1 2 hose to nose of injector to black coupler of capture bottle See Fig 2 2 Remove master cylinder lid and top off reservoir Loosen bleeder screw and attach 1 4 adapter fit ting for most OEM applications 3 16 Adapter is included for other applications See Fig 1 3 Pump injector until clean brake fluid is coming out of the caliper s using caution that the master cylinder reservoir does not run dry See Fig 2 4 Tighten bleeder screw Top off master cylinder reservoir to H D Factory Specifications Install lid and new gasket 5 Check for proper brake function If brake lever or pedal is spongy follow instructions for Bleeding Procedure below 6 Clean entire JIMS tool with denatured alcohol after use to prevent cross contamination between DOT 4 and DOT 5 brake fluids Initial Bleeding Procedure 1 Remove master cylinder lid and make sure reservoir is nearly empty Turn handlebar so the master cylinder sits in a near level position If banjo fitting is higher than the master cylinder it will trap air 2 Fill JIMS bottle with the brake fluid specified for your bike A magnet is supplied on the bottle holder to hang in a convenient place near the brake caliper See Fig 1 3 Prime the hose before attaching to the bleeder valve Connect inlet h2. specification per year and model in the H D service manual 10 Check pedal or lever for lt oma Master Cylinder fi f Eor Depress lever po Irmness ever IS SOTt O anita quia ser _ spongy repeat procedure PERWieseesente a until firm on 11 Top off brake fluid in mas ter cylinder reservoir to H D service manual specifica tions Install new master cylinder gasket and lid Tighten screws per service manual torque specifica tions Verify brake lamp operation Test for proper brake function before entering public roads Caliper 1 Inject fluid into 1 bleeder valve Petfotmance Taria fot Harley Davidson Mototajptes 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 3 No 738 IS REV N C 3 12 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TOOL No 738 Dual Caliper Techniques 1 Follow basic guidelines from initial bleeding procedure above 2 Depress brake lever about half way using a zip tie or tie strap This prevents fluid from entering the master cylinder 3 Open bleeder valve on caliper 2 and attach a hose and catch bottle not supplied See Fig 4 4 Prime the JIMS injector tool as listed in Fig 3 on page 3 5 Loosen bleeder on caliper 1 and attach fitting See Fig 4 6 Squeeze the handle to force fluid into caliper 1 through brake line to caliper 2 and finally into the catch bottle Repeat until no air is noticed in th
3. No 738 IS REV N C 3 12 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TOOL NO 738 JIMS REVERSE eee _ lt BRAKE BLEEDING ER C TOOL BY PHOENIX SYSTEMS No 738 Use on all hydraulic brake and clutch Injector Volume systems Control This tool can be used to flush brake systems or to bleed Hydraulic systems when replacing lines calipers mas ter cylinder or brake light switch Injector Note On most Harley Davidson ABS systems the final bleeding proce gem dure must be done by an authorized Harley Davidson dealer using a Digital Technician II Important Note Read complete instructions thoroughly before using this tool ALWAYS WEAR SAFETY GLASSES OR OTHER FACE AND EYE PROTECTION SUCH AS FULL FACE SHIELD JIMS IS NOT RESPONSIBLE FOR DAMAGE INJURY OR THE QUALITY AND SAFETY OF YOUR WORK WARNING Before tool use verify the type of brake fluid that your bike uses Mixing DOT 4 and DOT 5 brake fluid will cause damage to your brake system Check the master cylinder lid if you are not certain which type of brake fluid your bike uses or check appropriate H D service manual for the model and year of your bike DOT 4 brake fluid is harmful to painted surfaces body panels and is an eye irritant Always use caution and protect all painted surfaces from spills When switching brake fluids from Dot 5 to Dot 4 or reverse always flush tool system using denatured alcohol Flush tool a
4. e clear tube attached to caliper 2 See Fig 4 7 Remove the device that is depressing the brake lever and continue injecting brake fluid until air bub bles in master cylinder reservoir cease See Fig 4 8 Disconnect adapter from bleeder on caliper 1 wait until only fluid leaks out and tighten bleeder screws on both calipers 9 Check for proper operation 10 If lever is spongy reverse procedure and inject fluid into caliper 2 11 Top off brake fluid in master cylinder reservoir to H D service manual specification install new mas ter cylinder gasket and lid Tighten screws per service manual torque specifications Verify brake lamp operation Test ride the bike to verify proper brake function before entering public roads CAUTION WEAR SAFETY GLASSES OVER YOUR EYE S SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Tavis fot areg Davidsoni Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 4
5. fter each job is performed to prevent cross contamination After service always check that brakes are functioning properly before entering public roadways Failure to properly bleed brake systems could leave air in the hydraulic brake system which reduces brake efficiency and could result in death or serious injury CAUTION WEAR SAFETY GLASSES OVER YOUR EYE S SEE JIMS CATALOG FOR HUNDREDS OF TOP QUALITY PROFESSIONAL TOOLS THE LAST TOOLS YOU WILL EVER NEED TO BUY Petfotmance Faia fot tlatley Vavitlton Motorcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 1 No 738 IS REV N C 3 12 A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TOOL NO 738 Some ABS models require final bleeding using a Digital Technician Il This service is only provided by authorized Harley Davidson dealers Check your H D service manual Recommended tools and supplies e Phillips screwdriver e Denatured Alcohol 3 8 box wrench e Model specific brake fluid Safety glasses e H D Service Manual per year and model being serviced e Replacement master cylinder gasket Setting the Volume of the Injector The Injector tool has an adjustable vol ume selector that can pump from one to Brake Fluid EF twelve milliliters per stroke Use the max i imum setting of 12 ml If the fitting pops Pad lt gt Black i Fa Coupler no off of the bleeder screw turn the selector down
6. ose from the coupler with the Petfotmance Feria fot arkey Davidsoni Norowcycles 555 DAWSON DRIVE CAMARILLO CA 93012 PHONE 805 482 6913 FAX 805 482 9224 2 REV N C 3 12 No 738 IS A Division of Thiessen Products Inc INSTRUCTION SHEET FOR TOOL NO 738 black ring on the bottle to the vacuum side of the Injector Connect the 15 1 2 hose to the white cou pler of the bottle and pump tool until all air is evacu ated from the tool and lines Disconnect the hose from the white fitting and replace the red Luer cap See Fig 3 4 Connect the proper bleeder fitting to the end of the hose outlet It should fit snugly onto the bleeder screw Most Harley Davidsons use the 1 4 fitting 5 Never let the fluid level get below one inch from the ikamikak KAMIAS bottom of the bottle FIG 3 6 Loosen the bleeder valve approximately 3 4 turn 7 Connect the adapter to bleeder valve 8 Pump brake fluid into the bleeder valve observing the master cylinder reservoir for air bubbles escap ing from the vent port Make sure brake fluid does not overflow the master cylinder reservoir If fit ting pops off bleeder valve the injection volume is too high Turn down the setting on the JIMS injec tion tool See Fig 1 9 When air bubbles have stopped and only fluid is filling the reservoir remove fitting from the bleeder screw wait a moment until all air escapes and only fluid comes out tighten bleeder to the torque
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