Converting Roadster over to Classic Footboard kit - QUESTIONS!!

cadconversions said:

Quick update - lifecycle took care of me and their reputation is well deserved. Hope to start on the conversion soon and will post some step by step photos

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cadconversions said:

Quick update - lifecycle took care of me and their reputation is well deserved. Hope to start on the conversion soon and will post some step by step photos

Click to expand...

cadconversions said:

I've got it all done and actually removed and with pics ready. You don't have to lose the ABS and the answer is as close as your kitchen or Wal-Mart. I'll be back soon as I get home and update everyone



Worked great!

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mikewd said:

Ready to rummage kitchen or fly to walmart...bike-less and desperate, lol!

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• I unscrewed the retaining bolt on the gear shaft and then gear lever slid off easily.
• I then removed three bolts from the front of the rail and two from the rear and the rail is off.
• The kit didn't come with any ball / socket connections so I had to reuse the ones from the roadster. However, I did have to purchase a new gear lever actuator (picked up the aftermarket chrome model) and the socket / turnbuckle from a parts supplier (used Calmoto.com)
• I removed the wire retaining pieces from the roadster ball joints and reinstalled on the new floorboard pieces.

• Install the new rails to the holes on the motor - exactly where the old rails were removed.
• With the gear shift assemble ready - install the gear actuator on the shaft getting the correct teeth alignment set of the shifter.
• Install the collared bolt to hold the gear lever. Do not over tighten or it will not work as smoothly as you want.
• Install the floorboard - making sure to get the springs aligned and the pin passing through the spring. Much easier than it originally looked.

• Remove the brake line between the abs module and the brake reservoir / assembly
• Once done, use a star wrench to remove the ABS module (single screw) from the roadster's rail. Just let the ABS module dangle for a moment.
• Unscrew the rails from the motor block and everything comes off with the rail

• Install the new brake side rails
• Attach the brake lever with return spring.
• You'll also need a new brake reservoir/Master Cylinder from an earlier model rocket (I purchased an 2005) or it's reported that you can buy one from a Speed Triple as well.
• Install the new (older model) brake reservoir / Master Cylinder assembly onto the rail and connect to the brake lever. If you didn't have the ABS you would just about be done... However, you have a Roadster!
• You'll need to fabricate a bracket to hold the ABS module. The easiest solution is us the two bolts that mount the brake reservoir assembly to the rail. You can come off those two bolts and make a stainless plate of adequate thickness to fit.
• There's a drawing available with a bracket for the flatter floorboards. However, since mine was the model that set higher and angled - it wouldn't work. However, the whole spacing was the same.
• I made a very thin metal template with tin snips and thin metal from a hobby shop to before making out of a thicker stainless piece of metal.
• I've attached a final pic of my stainless bracket. I spent a long time trying to find stainless of adequate thickness (2-3mm) that didn't cost a fortune. My wife came to the rescue - she brought me a stainless steel spatula from her cooking utensils that was the perfect thickness.
• I used a band saw, step drill bits, and time and cut it out myself. I did end up taking the finished metal to a shop and having them bend and grind the edges smooth for me (didn't charge me a thing for it)
• Bolt everything up, install the ABS module to the new bracket, attach everything to the brake lever and you are almost finished.
• I need a 4.5" custom brake line with banjo bolts on each end. I never did get one made up and just bent one I had one hand to make it work to make sure before I spent the money to have a brake line made. Be sure to do final measurements before ordering because your bracket design, etc... may change the exact length that you need to order.

cadconversions said:

The brake side is a little more complicated and requires making a bracket to hold the ABS module that's attached to the roadster's rail.

To remove the brake rail:

• Remove the brake line between the abs module and the brake reservoir / assembly
• Once done, use a star wrench to remove the ABS module (single screw) from the roadster's rail. Just let the ABS module dangle for a moment.
• Unscrew the rails from the motor block and everything comes off with the rail

To install the new brake side rail:

• Install the new brake side rails
• Attach the brake lever with return spring.
• You'll also need a new brake reservoir from an earlier model rocket (I purchased an 2005) or it's reported that you can buy one from a Speed Triple as well.
• Install the new (older model) brake reservoir assembly onto the rail and connect to the brake lever. If you didn't have the ABS you would just about be done... However, you have a Roadster!
• You'll need to fabricate a bracket to hold the ABS module. The easiest solution is us the two bolts that mount the brake reservoir assembly to the rail. You can come off those two bolts and make a stainless plate of adequate thickness to fit.
• There's a drawing available with a bracket for the flatter floorboards. However, since mine was the model that set higher and angled - it wouldn't work. However, the whole spacing was the same.
• I made a very thin metal template with tin snips and thin metal from a hobby shop to before making out of a thicker stainless piece of metal.
• I've attached a final pic of my stainless bracket. I spent a long time trying to find stainless of adequate thickness (2-3mm) that didn't cost a fortune. My wife came to the rescue - she brought me a stainless steel spatula from her cooking utensils that was the perfect thickness.
• I used a band saw, step drill bits, and time and cut it out myself. I did end up taking the finished metal to a shop and having them bend and grind the edges smooth for me (didn't charge me a thing for it)
• Bolt everything up, install the ABS module to the new bracket, attach everything to the brake lever and you are almost finished.
• I need a 4.5" custom brake line with banjo bolts on each end. I never did get one made up and just bent one I had one hand to make it work to make sure before I spent the money to have a brake line made. Be sure to do final measurements before ordering because your bracket design, etc... may change the exact length that you need to order.

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mikewd said:

Can't begin to tell how much I appreciate the time you tool to explain this. Did u reuse the mastercylinder as you said all you needed was a new resevior. the resevor looks,identical

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