Black Max BX-1000 Brake System Installation Guide

Black Max BX-1000 Brake System

INSTALLATION GUIDE

PLEASE READ THROUGH THE ENTIRE MANUAL BEFORE INSTALLING YOUR BRAKE SYSTEM

IMPORTANT DO NOT USE ANY OTHER SEALS OTHER THEN WHAT IS SUPPLIED WITH THIS SYSTEM.

INCOMPATIBLE SEALS WILL RESULT IN SYSTEM FAILURE

IMPORTANT USE ATF FLUID ONLY (Automatic Transmission Fluid) ANY OTHER FLUID MAY DAMAGE THE SYSTEM
IMPORTANT DO NOT USE BRAKE FLUID WITH THIS SYSTEM. BRAKE FLUID WILL DAMAGE THE SEALS
IMPORTANT DO NOT EXCEED THE GROSS WEIGHT LIMIT OF 1000 LBS
IMPORTANT USE PROVIDED LOCK NUTS AND LOCK WASHERS TO PREVENT WHEEL FROM LOOSENING
IMPORTANT REPLACE TIRES ANNUALLY OR WHEN SHOWING EXCESSIVE WEAR.
IMPORTANT DO NOT USE IF THERE IS ANY SIGN OF LEAKING. MAKE REPAIRS IMMEDIATELY
IMPORTANT MOUNT CALIPER WITH A BLEEDER SCREW LOCATED IN THE TOP POSITION ONLY. USE THE NYLON TIPPED SET SCREWS TO PLUG THE TWO OTHER UNUSED BLEEDER SCREW LOCATIONS.
IMPORTANT MOUNT THE MASTER CYLINDER IN AN UPRIGHT POSITION TO PREVENT OIL FROM LEAKING FROM THE VENT PLUG.
IMPORTANT NOTICE THE ATF HYDRAULIC FLUID WILL DISCOLOR IN DIRECT SUN LIGHT AND SHOW CLEAR IN SOME AREAS AND WILL APPEAR AS IF THERE IS AIR IN THE LINES
IMPORTANT ALWAYS REPLACE THE NYLOCK AXLE NUT AFTER REMOVING IT MORE THEN TWO TIMES
IMPORTANT MAKE SURE THE AN10 WASHER IS LOCATED BETWEEN THE HUB ASSEMBLY AND CALIPER (See Assy. Drawing)
IMPORTANT ONLY USE THE BRAKE LINE SUPPLIED WITH KIT OR A CUSTOM FITTED ALUMINUM BRAKE LINE

(Other plastic line may look similar but will not hold the pressure resulting in weak and spongy braking performance)

1. Mount Tire (See Split Rim Section for Mounting Split Rims)

Apply soapy water to edge of tire bead and wheel rim. Apply the tire to the rim and spread it apart. Connected to the air chuck to valve stem and with the air flowing into rim pinch the ends of the tire to spread the bead of the tire until the tire seats and pops on to the bead on both sides. Inflate to desired pressure. Note the stock tire is a 4.00-6 tire that is installed on both the 4” and 6” wide rims. See the installa-tion videos on our website for more info (www.flyfbi.com/html/hydraulic_brakes.html)

2. Mount Hub To Wheel

Attach the hub to the wheel on the opposite side of valve stem with supplied hex headed bolts. Apply the flange nuts to the back side of hex headed bolts to secure hub to wheel.

Note: Make sure to insert lock washers under the bolt head

3. Mount Axle to Frame

Tap woodruff key into the axle and attach the sup-plied 5/8” axle to your frame. (Note the caliper can be
mounted vertical or horizontal by locating the bleeder screw at the highest location (plugging the other two with the sup-
plied plugs) Locate the desired position of the axle before drilling the axle.
(Note: You may need to fabricate your own mounting system or contact FBI for custom made mounting hardware.)

4. Apply Sealant To Fitting
Apply either loctite sealant or Teflon tape to the straight thread of the compression fitting. Rap the tape in the direction shown in the picture or use loctite 592 thread sealant instead of the tape.
Note: sealant is not used on the plugs or the bleeder screw

5. Install Caliper Hardware

Tighten down the bleeder screw plugs into the op-posite holes of where you are going to locate your bleeder screw at the highest position of the piston. When the plugs are inserted the nylon tip will form to the shape of the seat. (Do not over tighten)

6. Install Caliper to Axle

Tighten up the compression fitting and insert the caliper on to the axle and slide it over the woodruff key.
Make sure you use sealant on the pipe thread side of the fitting. Teflon tape or loctite thread sealant.

7. Install Brake Line and Compression Fittings

Secure the caliper to the axle by tightening the set screw located at the bottom of the caliper.

Connect the straight compression fittings to the cali-pers and master cylinder making sure to use either Teflon tape or loctite thread sealant on the pipe threads only. You do not need to seal the threads on the bleeder screw, bleeder screw plugs, or the compression fitting threads, just the pipe threads going into the caliper and the master cylinder. Using the “T” connecter, route the brake line and connect both calipers to the master cylinder by inserting the brake line about 1/2” through the male compression fit-ting into the female fitting keeping the line inside fitting as far as it will go and then tighten the ferrule part of the fitting finger tight and then 1-3/4 more turns.

Note: On the straight compression fitting the ferrule will break free from the male compression fitting once it has been tightened and crimp on to the brake line. The TEE compression fitting will also crimp on to the brake line after the nut has been tightened. It is a good idea to lube the ends of the tubing by dipping them in the ATF fluid before inserting into the compression fitting.

Important: Install the AN10 washer between the hub assembly and the caliper. This will prevent the hub from rubbing against the caliper and will provide the proper spacing for the rotor.
Route the line between the calipers and the TEE keeping the distance as short as possible.
Make sure to use Teflon tape or pipe sealant on pipe threads going into the caliper

8. Insert The Rotor

Slide the rotor over the axle and between the pads in the caliper. Hold it there while sliding the wheel hub assembly on to the axle.

9. Mount the Wheel

Slide the wheel on to the axle and locate the pins (Socket Head Cap Screws) on the Azusa adaptor to the holes on the rotor. Slide the wheel up tight and make sure the pins are still located in the holes of the rotor.

10. Secure the Locknut

Tighten main axle nut up slightly snug and back it up 1/4 turn or until wheel spins freely.
Note: This rotor is a full floating rotor and does not have any other mounting hardware to fasten to the wheel hub.

11. Mount Master Cylinder

Slide Master cylinder over 1” control stick locat-ing the brake handle forward and secure by tight-ening the clamp screw. Remove reservoir plug and fill the chamber with Hydraulic Fluid or ATF fluid. Crack the bleeder screw and bleed the air from the lines and caliper. Note you will need to aid more oil after every 2 pumps. Continue until all the air is gone and hold pressure on the handle and retighten the bleeder screw. Repeat this for the other caliper. Once you have bleed the system leave the oil level below the depth of the plug to prevent seepage when reinserting the cap.

Black Max Split Rim

Assembly Instructions

WARRANTY

1 YEAR LIMITED WARRANTY ON ALL PARTS ONLY UNDER CONDITIONS OF NORMAL AND INTENDED USE. MISUSE, DAMAGE OR ALTERATION OF ANY COMPONENT VOIDS THE WARRANTY.

BRAKE PADS AND ROTORS ARE EXCLUDED FROM WARRANTY

USE OF ANY OTHER FLUID OTHER THAN ATF FLUID VOIDS THIS WARRANTY.

NO OTHER WARRANTIES WRITTEN, VERBAL, IMPLIED OR OTHER THAN LISTED HERE WILL BE HONORED.

1380 LEGION ROAD
DETROIT LAKES, MN 56501
PHONE: 218-847-2862 800-850-3708
Website: www.blackmaxbrakes.com or www.fly- fbi.com
Email: [email protected]

Specifications:

• Model: BX-1000 BLACK MAX

• Color: Black

• Fluid Type: ATF Hydraulic Fluid

• Compatibility: Use only supplied seals and specified brake lines

• Mounting Position: Upright for master cylinder

Frequently Asked Questions (FAQ)

Q: Can I use any type of brake fluid?

A: No, only ATF Hydraulic Fluid should be used with this system to prevent system failure.

Q: Can I use plastic brake lines instead of aluminum?

A: No, plastic lines may appear similar but will not hold pressure, resulting in weak braking performance. Use the supplied brake line or custom-fitted aluminum line.

Q: How should I position the bleeder screw for optimal air bleeding?

A: The bleeder screw (Item 4) must be located in the top position to ensure all air is bled from the system. Use item 8 to plug other bleeder screw locations if needed.

References

• Black Max Brakes
• Black Max Brakes
• FlyFbi.com is for sale | HugeDomains

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