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Master Cylinder rebuild ( Front '80 1000S

Vmass

Vmass

Forum Sage
Past Site Supporter
I am in the process of completely redoing the front bakes.

I tore the MC apart and I am attempting to reassemble. I am having a heck of a time getting the snap ring back in (ring was part of the rebuild kit).

I assume it needs to make it the the second slot, the 1st one being for the dust boot.

Any tips?
 
Vmass said:
I am in the process of completely redoing the front bakes.

I tore the MC apart and I am attempting to reassemble. I am having a heck of a time getting the snap ring back in (ring was part of the rebuild kit).

I assume it needs to make it the the second slot, the 1st one being for the dust boot.

Any tips?
Click to expand...

Yes, second groove.

It's not easy to get it seated all the way. Sometimes the washer is a tight fit in the bore and needs to be pushed down first.

Good luck
 
You need a circlip pliers, it will slide in, in a nano second. Harbor Freight for $2.49 with your 20% off coupon.
 
Well, I just managed to get the circlip in place. Now I'm working on the dust boot.

How do you know when this is in the right spot?!! This has been the least fun project to date on this bike.
 
Vmass said:
Well, I just managed to get the circlip in place. Now I'm working on the dust boot.

How do you know when this is in the right spot?!! This has been the least fun project to date on this bike.
Click to expand...

Oh trust me they get better..:D
 
I ended up using a Q Tip to push the dust cover in place. Still no real way to tell if it seated propoerly.

Any way to test the caliper prior to reassembly?
 
With the MC rebuilt, should I see movement looking through the large hole of the reservoir body, as I compress the piston?

The piston compresses, but I do not see anything moving through the hole. I do see the corner of what appears to be the non-round piece of the rebuild kit.
 
Vmass said:
With the MC rebuilt, should I see movement looking through the large hole of the reservoir body, as I compress the piston?

The piston compresses, but I do not see anything moving through the hole. I do see the corner of what appears to be the non-round piece of the rebuild kit.
Click to expand...

I think you are ok, can you see the spring and small plunger out in front of the piston?
 
The large hole is on the back side of the piston, you probably won't see much there.

Did you clean out the small hole that is in the bottom of the reservoir? It would be just "downstream" of the large hole. In normal operation, it would be open between the reservoir and the brake hose, and would have the leading edge of the piston right next to it. The first couple of millimeters that the piston moves will cover the small hole and allow pressure to build in the hoses.

Not cleaning the small bleed hole is a common mistake that will lead to locked brakes in about five miles.

.
 
jwhelan65 said:
I think you are ok, can you see the spring and small plunger out in front of the piston?
Click to expand...

Not sure what I am looking at, I just thought I should see movement through the large hole as the piston is compressed....just checking as I prefer to do things just once.

I cleaned both small holes, one in main reservoir and the other small hole in the other section of the MC.

If I insert a wire in the small hole and then gently compress the piston, will that tell me it is operating correctly?
 
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