sleeving a master cylinder

[woodgeek]

Hi guys,
I was wondering if anyone has any experience sleeving a master cylinder. My '81 GPz550 has a badly pitted master cylinder and I'd like to get a stainless sleeve put into it. All of the shops I've called only do work on automobile master cylinders. Seems like installing a sleeve is something a relatively handy person could do themselves. What do you guys think?

[Agemax]

GPZ550???????? I think you are on the wrong website!

[Nessism]

It's doable with the right tools. I think you will have to make up a sleeve on the lathe of the right size, ID slightly small. Bore your master, press in the sleeve, then hone the sleeve to the proper size. Not a trivial task, and you will have to invest in some tools. There are companies that will do the work for you for a fee. http://applehydraulicsonline.com/pages/motorcycles-1

[eil]

In other words, buy a new master cylinder.

[tkent02]

In other words, buy a new master cylinder.

No kidding.

[woodgeek]

Thanks guys. I know, wrong site for a GPz, but master cylinder questions are sort of universal. ;-)
And I do own a GSX1100G :-)

I'd buy another master cylinder but for that year they're as rare as hens teeth. If I did find a used one, odds are it would have pitting too. I'd buy a new universal master cylinder but I'm trying to keep the parts stock or period correct after market.

[Nessism]

I've got a GPz550 rear master cylinder on my KZ750. The only thing different is the GPz part is black. You can expand your search with this knowledge but I can confirm that it's hard to find a good master.

[woodgeek]

I've got a GPz550 rear master cylinder on my KZ750.

Thanks Ed. I'm going to give Apple a call. Having a large base of parts to share between the KZ's and GPz's is nice. With the front master cylinder, a lot of the bikes had a single disc front while this master cylinder for dual discs is only shared between the 81 GPz550 and the 81GPz1100. I've pored over the parts diagrams no similar master cylinders are used by Kawa. I'm going to begin looking at the Suzuki and Honda parts databases as I'm sure Tokico made masters for them as well. I know that the GSXR's used Tokico (sometimes Nissin) masters. I'm not sure about the GS masters.

[Nessism]

Thanks Ed. I'm going to give Apple a call. Having a large base of parts to share between the KZ's and GPz's is nice. With the front master cylinder, a lot of the bikes had a single disc front while this master cylinder for dual discs is only shared between the 81 GPz550 and the 81GPz1100. I've pored over the parts diagrams no similar master cylinders are used by Kawa. I'm going to begin looking at the Suzuki and Honda parts databases as I'm sure Tokico made masters for them as well. I know that the GSXR's used Tokico (sometimes Nissin) masters. I'm not sure about the GS masters.

Are you going for a concourse quality restoration or are you just trying to build a nice bike and stay within Kawasaki's design intent? Assuming the later, then you can use just about any master with a 5/8" bore. Some of the masters have an angle on the reservoir but that typically isn't critical as long as you keep the fluid level up. For my 750 I'm using a master from a Kawasaki EX650. You can pick up low mileage units for about $40 shipped or less. There are lots of generic masters for sale these days too. Check ebay. Some list a 16mm master cylinder bore but that's close enough to 5/8" so as to be interchangeable. Building a master cylinder is quite simple so I wouldn't worry too much about buying a Chinese part.

If on the other hand you ARE going for an accurate restoration, then get your master sleeved since that's the best way to assure you get the right part.

Good luck