INSTALLATION PROCEDURE for BRUTE IV EXTREMETM
MID-CONTROLS (PART NO. 2084-0504)
NOTE: USE BLUE LOCTITE ON ALL FASTENERS
TORQUE 1/4” fasteners to 120 inch pounds . . . 5/16” fasteners to 30 foot pounds . . . 3/8” fasteners to 42 foot pounds
BRAKE SIDE ASSEMBLY (P/N 2084-0502) / INSTALLATION PROCEDURE
1. Remove the battery per O.E. manual.
Photo 1
2. Remove the exhaust system per O.E. manual.
3. Remove the stock forward brake controls & brake line per O.E. manual.
4. Remove the three(3) lower 5/16-18 socket head cap screws on the
bottom right side of the transmission. (Photo 1)
5. Remove the top front 1/4-20 socket head cap screw on the right side of
the transmission. (Photo 2)
6. Install supplied 1/4-20 set screw into the top front hole (P/N 2100-0049)
on the right side of transmission. (Photo 3)
Photo 2
7. Install supplied threaded spacer (P/N 2084-0079) over stud with the hex
end towards the transmission and torque to 12 foot pounds. (Photo 4)
8. Install the brake assembly onto the transmission using three(3) each
5/16-18 x 3.00” socket head cap screws (P/N 2100-0001) with
spacers (P/N 2084-0069) and one(1) each 5/16-18 x 1.00” socket
head cap screw (P/N 2100-0047). (Photo 5A)
9. Check the working of the brake pedal up & down to make sure nothing
is rubbing or hitting any of the linkage or pedal (the plunger rod will stop
when it touches the front lower spacer and at this time the master cylinder
will be bottomed out). (Photo 5B)
10. Adjust the free play in the brake lever. You should have 1/8” up & down
free play. This can be adjusted with the plunger rod (P/N 2084-0065).
Loosen jam nuts then turn the plunger to add or take away free play.
When you have 1/8” of free play lock the jam nut (P/N RIV-201) to the
rod end (P/N 2018-0099). (Photo 6)
Photo 3
2100-0049
Photo 4
11. Now it’s time to measure for your rear brake line and light switch. Be
sure to run the brake line away from the exhaust system and any
moving parts. Once you’ve installed the brake line you can bleed the
brake system per the O.E. manual.
12. Install your footpeg and brake pedal peg (not supplied).
2084-0079
13. Reinstall your exhaust system & check for clearance.
Photo 5A
Photo 5B
2084-0069
2084-0079
2100-0001
2100-0047
OE=Original Equipment
SHCS=Socket Head Cap Screw
SFHCS=Socket Flat Head Cap Screw
2018-0099
RIV-201
2084-0065
Photo 6
1108-0046 / 6-08
BRAKE SIDE ASSEMBLY. . . P/N 2084-0502
ITEMIZATION OF PARTS
* NOTE: USE BLUE LOCTITE ON ALL FASTENERS
Master Cylinder Assembly
Qty
1
1
1
1
2
1
Part Number
Description
2034-0051
2037-0001
2034-0056
2094-0001
2100-0112
2084-0412
Polished Master Cylinder Body
Master Cylinder Rebuild Kit
Polished Master Cylinder Top Cover
Master Cylinder Top Cover Gasket
10-24 x .500” Top Cover Screws
Master Cylinder Assembly
Photo 1 & 2
Photo 1
Photo 1
Photo 1
Photo 1
Photo 2
Master Cylinder Assembly to Brake Mounting Plate
Qty
1
2
2
2
2
Part Number
Description
2084-0063
2100-0045
2084-0076
RIV-318
Polished Brake Mounting Plate
3/8-24 x 2.75” SHCS
Spacers (Master Cylinder)
3/8” Flat Washers
3/8-24 Locknuts
Photo 3
Photo 3
Photo 4
Photo 4
Photo 5A
Brake Pedal Ext. Spacer Assembly
Qty
1
2
Part Number
Description
2084-0066
2084-0048
Brake Pedal Ext. Spacer
Bronze Bushings
Photo 6
Photo 6
Brake Pedal Ext. Spacer Assembly to Brake Mounting Plate
Qty
4
1
1
1
Part Number
Description
2100-0113
2100-0042
2084-0071
2084-0409
1/4-20 x 1.00” SHCS
1/4-20 x 1.375” SHCS
Chrome Spacer for P/N 2100-0042
Brake Pedal Ext. Spacer Assembly
2100-0112
Photo 7
Photo 7
Photo 7
Photo 7
2084-0412
M/Cylinder
Assembly
2084-0076
2094-0001
2034-0056
2100-0045
RIV-318
Rubber
Cup Seal
O-Ring
Photo 1
2034-0051
Photo 4
2037-0001
2084-0063
Photo 2
Photo 3
Photo 5A
RIV-318
Photo 7
2100-0113
Photo 6
2084-0076
2084-0066
2084-0063
2084-0048
2084-0071
2100-0042
Brake Side Assembly & Brake Linkage Assembly
Qty
Part Number
1
3
1
1
1
1
Description
Welded Brake Linkage
.125” x .750” Dowell Pins
Brake Shaft Spacer
Curved Disc Spring Washer
Thrust Washer (Small)
Thrust Washer (Large)
2101-0008
2084-0075
1100-0018
1101-0020
1101-0022
Photo 8
Photo 8 & 9
Photo 8 & 10
Photo 10
Photo 10
Photo 11
Master Cylinder Plunger Rod Assembly
Qty
Part Number
1
1
1
1
1
1
1
2018-0099
2084-0065
RIV-201
1101-0023
2100-0043
2084-0073
2100-0044
Description
Rod End 5/16-24 Female
Plunger Rod
Jam Nut for Rod End on Plunger Rod
Return Spring
5/16-24 x 1.25” SFHCS
Spacer (Rod End)
5/16-24 Center Locknut
Photo 8
Photo 9
Photo 12
Photo 12 & 13
Photo 13
Photo 13
Photo 12 & 13
Photo 12 & 13
Photo 12 & 13
Photo 10
2084-0075
1100-0018
2084-0075
1101-0020
1101-0022
1101-0020
1100-0018
Photo 11
1101-0022
2101-0008
2084-0093
Photo 12
2100-0043
2100-0044
2084-0073
2018-0099
1101-0023
RIV-201
2084-0065
2100-0044
1101-0023
2084-0073
2100-0043
Photo 13
Brake Lever Assembly
Qty
1
1
1
7
1
Part Number
Description
2084-0055
2084-0053
2084-0073
2100-0048
2100-0047
Brake Lever Mounting Block
Brake Lever
Brake Lever Retainer
10-24 x 1.125” SHCS
5/16-18 x 1.00” SHCS
Photo 14
Photo 14
Photo 15A
Photo 15B
Photo 15B
Installing Brake Lever Assembly to Brake Mounting Plate
Qty
1
1
Part Number
Description
Brake Mounting Plate Assembly
Brake Lever Assembly
Photo 16A/B
Photo 16A/B
Installing Spacers onto Brake Mounting Plate
Qty
3
1
3
1
1
Part Number
Description
2100-0001
2100-0047
2084-0069
2084-0079
2100-0049
5/16-18 x 3.00” SHCS
5/16-18 x 1.00” SHCS
Spacers
Spacer
1/4-20 x 1.50” SSS
Photo 14
Photo 14
Photo 17/18
Photo 17/18
Photo 17/18
Photo 17/18
Photo 17/18
Photo 15A/B
2084-0073
2100-0048
2084-0053
Line-up Hole
2084-0055
Photo 16A
Retainer
Retaining
Block
Top Front
Photo 17
2084-0069
2084-0079
Photo 16B
1101-0022
2100-0047
2100-0047
2100-0001
Photo 18
2100-0049
2084-0079
2084-0069
2100-0001
2100-0049
COMPONENT ASSEMBLY / BRAKE SIDE
1. Master cylinder rebuild kit (P/N 2037-0001). Lubricate rubber
cup seal & o-ring on piston with DOT 5 BRAKE FLUID.
(Photo 1A)
2. Install large end of spring into the master cylinder (P/N 20340051) bore with nylon pin inserted into small end of spring
followed by rubber cup seal (flat side of rubber cup seal faces
outward). (Photo 1A)
3 Spread a small amount of brake fluid in master cylinder base.
Install aluminum piston with the o-ring end facing outward and
push aluminum piston into the master cylinder bore and install
snap ring. (Photo 1B)
4. Install master cylinder top cover rubber gasket (P/N 20940001) with master cylinder top cover (P/N 2034-0056) using
two(2) each 10-24 x .500” SHCS (P/N 2100-0112) and hand
tighten. (Photo 1C)
Rubber Cup
Seal
2084-0412
2094-0001
2100-0112
2034-0056
2034-0051
M/Cylinder Assy
2084-0076
RIV-318
2100-0045
2084-0063
Photo 3
Photo 1A
O-Ring
Photo 1B
1. Install two(2) each 3/8-24 x 2.75” SHCS
(P/N 2100-0045) thru the two counterbored
holes at end of brake mounting plate (P/N
2084-0063) followed by two(2) each spacers
(P/N 2084-0076). (Photo 3 & 4)
2. Now slide master cylinder onto 3/8-24 x 2.75”
SHCS followed by two(2) each washers
(P/N RIV-318). (Photo 4)
Photo 1C
RIV-318
M/Cylinder Assy
2084-0076
Photo 4
2084-0063
Photo 6
2084-0066
1. Press two(2) each bushings (P/N 2084-0048) into each end of brake pedal
ext. spacer (P/N 2084-0066). (Photo 6)
NOTE: TRY INSTALLING WELDED BRAKE LINKAGE INTO BRAKE PEDAL
EXT. SPACER. THIS WILL LET YOU KNOW IF THE BUSHINGS
NEED TO BE REAMED.
2084-0048
Photo 7
2100-0113
1 Install brake pedal ext. into the machined and pocketed side of brake
mounting plate. (Photo 7)
2. Install four(4) each 1/4-20 x 1.00” SHCS (P/N 2100-0113) into counterbored
holes and then slide spacer (P/N 2084-0071) onto 1/4-20 x 1.375” SHCS
(P/N 2100-0042) and torque these to 12 foot pounds. (Photo 7)
2084-0071
2100-0042
1. Install three(3) each pins (P/N 2101-0008) into the three holes on the threaed
end of welded brake linkage. Using a hammer tap the three pins until they
bottom out. (Photo 8 & 9)
2. Install spacer (P/N 2084-0075) onto welded brake linkage (flat side facing out).
Now install curved disc spring washer (P/N 1100-0018) followed by small
thrust washer (P/N 1101-0020). (Photo 10)
3. Install welded brake linkage (Photo 10) onto brake mounting plate with brake
pedal ext. and master cylinder from the master cylinder side. Now slide the
large thrust washer (P/N 1101-0022) onto welded brake linkage from the
outside. (Photo 11)
NOTE: NOTCH ON WELDED BRAKE
LINKAGE GOES BEHIND SHCS
(P/N 2100-0042) & SPACER
(P/N 2084-0071) ON BRAKE
MOUNTING PLATE. (Photo 7)
2084-0075
1100-0018
Photo 8
Photo 9
1101-0022
1100-0020
2101-0008
2084-0075
1100-0018
Photo 11
1100-0020
Photo 7
Photo 10
1100-0022
1. Install jam nut (P/N RIV-201) onto threaded end of of plunger rod (P/N 2084-0065) followed by rod end (P/N 2018-0099). (Photo 12)
2. Install 5/16-24 x 1.25” SFHCS (P/N 2100-0043) into welded brake linkage. On the other side install spacer (P/N 2084-0073).
(Photo 13)
3. Now install spring (P/N 1101-0023) on machined end of plunger rod (P/N 2084-0065). Guide the plunger rod & spring into the
master cylinder and install rod end onto P/N 2100-0043 followed by center locknut (P/N 2100-0044). (Photo 13)
4. Torque to 30 foot pounds.
2100-0044
Photo 12
2084-0073
2100-0043
2018-0099
2100-0044
1101-0023
1101-0023
2084-0065
RIV-201
2084-0065
2018-0099
2084-0073
Photo 13
1. Holding brake lever mounting block (P/N 2084-0055) so top front
is facing you, install brake lever (P/N 2084-0053) onto brake
mounting block lining up the top two mounting screw holes
(NOTE: THE BRAKE LEVER WILL POINT TO YOUR RIGHT).
(Photo 14)
2. Now install brake lever retainer (P/N 2084-0073) with counterbored holes facing outward. Start by installing 10-24 x1-1/8” SHCS
(P/N 2100-0048) in top hole and now install 10-24 x 1-1/8” SHCS
in every other hole going downwards and tighten. (Photo 15A/B)
Photo 14
Photo 15A/B
Retainer
Retaining
Block
Top Front
1. Install brake lever with mounting block assembly onto welded brake linkage shaft that is installed
in brake mounting plate. The top hole on the brake mounting block will go in the top pin on brake
linkage shaft with thrust washer between the two.
2. Now tap the brake lever mounting block onto the welded brake linkage with a rubber hammer.
(Photo 16A)
3. Now install 5/16 -18 x 1” SHCS (P/N 2100-0047) thru center hole in brake lever mounting block
and thread onto welded brake linkage. (Photo 16B)
NOTE: YOU WILL USE THE 5/16 -18 x 1” SHCS TO PULL THE TWO UNITS TOGETHER
4. Now that the unit is complete remove 5/16 -18 x 1” SHCS and put one(1) drop of blue loctite
onto threads and torque to 30 foot pounds.
1. Install three(3) each 5/16 -18 x 3” SHCS (P/N 2100-0001) thru brake
mounting plate. Then slide three(3) each spacers (P/N 2084-0069)
onto 5/16 -18 x 3” SHCS.
2. Install one(1) each 5/16-18 x1” SHCS (P/N 2100-0047) into top hole
and thread round end of spacer (P/N 2084-0079) onto SHCS.
Thread 1/4-20 x 1.50” SSS into hex end of spacer (P/N 2100-0049).
2100-0043
2100-0049
2084-0069
Photo 16A
1101-0022
2100-0047
Photo 16B
2084-0079
Photo 18
2100-0047
2100-0001
INSTALLATION PROCEDURE for BRUTE IV EXTREMETM
MID-CONTROLS (PART NO. 2084-0504)
NOTE: USE BLUE LOCTITE ON ALL FASTENERS
TORQUE 1/4” fasteners to 120 inch pounds . . . 5/16” fasteners to 30 foot pounds . . . 3/8” fasteners to 42 foot pounds
SHIFT SIDE ASSEMBLY (P/N 2084-0500) / INSTALLATION PROCEDURE
1.
Remove primary covers and primary drive per O.E. manual.
2.
Remove the shifter and shifter mounting plate per O.E. manual.
3.
Remove block-off plug from motor plate & install supplied shifter crossover tube(P/N 2084-0050) (Photo 7A, 7B, 7C)
Photo 7B
Photo 7A
Photo 7C
2084-0050
Welded
Shifter
Linkage
4. Install spring washer (P/N 1101-0018) onto shifter shaft &
then thrust washer (P/N 1101-0022). Install shifter shaft
into shifter crossover tube. (Photo 8)
1101-0018
1101-0022
5. Install motor plate onto motorcycle per your BRUTE IV
EXTREMETM instructions.
6. Install belt drive and clutch per your BRUTE IV EXTREME
instructions.
Photo 8
TM
Photo 9
Shifter Rod Assy
7. Install the shifter rod to the shifter linkage
and shifter arm on transmission using
two(2) each 5/16-24 x 1.00” socket head
cap screws (P/N 1100-0017) & one(1) each
5/16-24 lock nut (P/N 2100-0044). (Photo 9)
2100-0044
1101-0017
1101-0017
Photo 10A
8.
Remove block-off cap from outer belt guard. (Photo 10A & 10B)
If your outer belt guard does not have a block-off cap
you will have to finish machining the shifter crossover
tube hole. (Photo 10C)
Photo 10B
Photo 10C
Photo 11
9.
Install the outer belt guard per BRUTE IV EXTREMETM
instructions.
10. Install thrust washer (P/N 1101-0022) over shifter shaft.
(Photo 11)
1101-0022
Photo 12
11. Install shifter yoke onto shifter shaft aligning the
three(3) each dowel pins on the shaft to the yoke
using one(1) each 5/16-18 x 1.00” socket head cap
screw to pull the yoke onto the shifter shaft and torque.
(Photo 12)
Shifter Lever Assy
12. Install footpeg and shifter peg.
13. Reinstall the battery.
SSHIFT SIDE ASSEMBLY. . . P/N 2084-0500
ITEMIZATION OF PARTS
* NOTE: USE BLUE LOCTITE ON ALL FASTENERS
Shifter Support Tube Assembly
Qty
1
2
Part Number
Description
2084-0050
2084-0048
Shifter Support Tube
Bronze Bushings
Photo 13
Photo 13
Shifter Lever Assembly
Qty
1
1
1
7
Part Number
2084-0055
2084-0053
2084-0073
2100-0048
Description
Photo 14
Photo 15A
Photo 15B
Description
Photo
Photo
Photo
Photo
Photo
Photo
Description
Photo 26
Shifter Lever Mounting Block
Shifter Lever
Shifter Lever Retainer
10-24 x 1.125” SHCS
Shifter Linkage Assembly
Qty
1
3
1
1
1
1
Part Number
2101-0008
1101-0018
1101-0020
1101-0022
2100-0047
Welded Shifter Linkage
.125” x .750” Dowell Pins
Curved Disc Spring Washer
Thrust Washer (Small)
Thrust Washer (Large)
5/16-18 x 1.00” SHCS
25
20
21
22
23
24
Shifter Rod End Assembly
Qty
2
1
2
1
Part Number
2018-0099
2084-0080
1100-0017
2100-0044
Photo 13
Rod Ends 5-16-24 Female
Rod 5/16-24 Male Each End
5/16-24 x 1.00” SHCS
5/16-24 Center Locknut
Photo 14
2084-0073
2084-0048
2084-0050
2100-0048
Photo 15A
2084-0053
Line-up Hole
Top Front
2084-0055
Photo 15B
Line-up Hole
Photo 20
Photo 21
2100-0047
Photo 22
2101-0008
1101-0022
1101-0018
1101-0020
Welded Shifter Linkage 2084-0091
Photo 23
1101-0018
2084-0050
1101-0020
Welded Shifter Linkage
Photo 24
Photo 25
1101-0022
Shifter Linkage
Assembly
Photo 26
2084-0081
2018-0099
2018-0099
COMPONENT ASSEMBLY / SHIFT SIDE
1. Press two(2) each bushings (P/N 2084-0048) into shifter support tube (P/N 2084-0050)
NOTE: TRY INSTALLING WELDED SHIFT LINKAGE INTO SHIFTER SUPPORT TUBE.
THIS WILL LET YOU KNOW IF THE BUSHINGS NEED TO BE REAMED.
2084-0050
2084-0048
NOTE: ASSEMBLY OF SHIFT LEVER IS THE SAME AS BRAKE LEVER ASSEMBLY, EXCEPT SHIFTER POINTS TO YOUR LEFT
1. Holding shift lever mounting block (P/N 2084-0054) top front install shift
lever (P/N 2084-0053) onto mounting block lining up the top two
mounting screw holes (NOTE: THE SHIFT LEVER WILL POINT TO
YOUR LEFT). Photo 15A
2. Now install the shift lever retainer (P/N 2084-0072) with counterbored
holes facing outward. Start by installing 10-24 x 1.125” SHCS
(P/N 2100-0048) in top hole and now 10-24 x 1.125” install SHCS in
every other hole going downwards and tighten. Photo 15B
2084-0072
2100-0048
Photo 15A
2084-0053
Line-up Hole
2084-0054
Top Front
Photo 15B
Line-up Hole
2101-0008
1. Install three(3) each pins (P/N 2101-0008) into the threaded end of
welded shifter shaft. Using a HAMMER tap the three (3) each pins until
they bottom out. Photo 21
2. Install the curved disc washer (P/N 1101-0018) onto the welded shifter
shaft, then slide on the thrust washer (P/N 1101-0020). Photo 22
3. Install the welded shifter linkage into the shifter support tube. Photo 23
4. Install thrust washer (P/N 1101-0022) onto the shaft & line-up the pin on
the welded shift linkage with the top hole on the shifter lever assembly.
Photo 24
5. Using a NO BOUNCE HAMMER give one light tap and start 5/16-18 x1.00”
SHCS (P/N 2100-0047).
Photo 21
1101-0020
Welded Shifter Linkage
Photo 23
Photo 22
1101-0020
1101-0018
Welded Shifter Linkage
1101-0022
1101-0018
2084-0050
1101-0022
2100-0047
Photo 24
2084-0081
2018-0099
2018-0099
1. Thread rod ends (P/N 2018-0099) onto the threaded rod (P/N 2084-0081) using blue loctite. When tightening the rod ends they
should both face the same way.
BRINGIN’ OUT THE BEAST !
Performance upgrades are
often obscured in such a way
that you really never get what
you’re looking for. After you
peel-off all the fancy trimmings
you’re basically left with about
what you started with.
Rivera Primo® delivers performance, plain & simple. Every go-fast
item has been tried & tested. We
work real hard at making sure your
buck will get you somethin’!
So, join us & the thousands worldwide who’ve made it a habit of
upgrading with the best . . . you
won’t be disappointed !
Start by gettin’ your hands on a Rivera Primo® parts catalog. It’s filled with the
goods that serious riders want, products that do perform. If you don’t have one
simply call us and ask for your copy of “BRINGIN’ OUT THE BEAST”.
RIVERA PRIMO INC.
12450 WHITTIER BLVD.
TEL: 562-907-2600
FAX : 562-907-2606
www.riveraprimoinc.com
WHITTIER, CALIFORNIA 90602
ORDERS: 800-872-1515