1996 Honda 900rr Front Master Assembly Conversion
Most people complain about how bad the XN85 brake feed back is. They say the brakes are just to mushy and takes a solid grab to brake hard which results in having the lever go just about all the way to the handle bar.
I like to use two fingers on the front lever when braking, but pinning the remaining fingers to the throttle grip when braking hard is no fun. I've replaced the recommended D.O.T. 4 (glycol-based) front brake fluid with D.O.T. 5 (silicone-based) for less mushiness in the lever. Since then I've been advised against using #5 (causes the caliper seals to swell I'm told). Better to use the new #5.1 fluid which is also glycol-based. Disconnecting the anti-dive and installing braided steel brake lines will improve lever feel even more.
This Modification will remedy all of this and you can still keep the anti dive hooked up. I had installed Steel Braded Brake Lines which also help but this is the best bang for the buck. You can buy the setup on Ebay all day long for around 30-40 US dollars. I used the 1996 because the lever was black like on the XN85, a 1995 will work too but its polished aluminum.
Place a cloth under your Master cylinder because some fluid is bound to spill while doing this so you don't want to ruin the paint job.
Next take a 14mm socket or open end wrench and loosen the brake line from the cylinder, make sure to set aside the copper washers from this step as you will reuse them.
Take a 8mm socket and undo the back bracket to the Master Cylinder that holds it to the handle bar and set it aside you will reuse this peace as it holds your mirror on.
Take the 900rr Master Cylinder and hold it in place as you bolt the XN85 bracket on you set aside in the previous step. Reconnect your brake line and bolt it together, make sure you have the copper washer on both sides of the brake line mounting surfaces or you will have a leak.
Now most important is bleeding the brakes. I use a a clear tube about 18 inches long with a cup of brake fluid filled about 2 inches to assist so no air backs up into the line as I bleed them. Use a 8mm open end box end wrench for this procedure. first bleed the piston caliper then bleed the anti dive system on each side. I know this is a long process but its for your safety.
Last you have to make the brake light wire fit the 900rr switch. You can buy the small clips at your local Pepboys or favorite store to wire it all up. Now look at the finished product. You should be able to brake hard with two fingers even with the stock brake lines. What is even better is the fact that you can adjust the brake feed back to your likeness with the dial on the lever.
