Excellent how to on servicing the master cylinder. I took mine apart 6 months ago and had to watch your great vid on how it goes back together Thanks 😊 👍
Beautiful job. What did you use to work on the brake fluid lid (cover) with the Yamaha writing on it? Mine looks awful and I'm afraid of sanding it with anything because I don't want to accidentally remove the writing.
I usually use paint stripper when I am doing these kind of jobs. then a light sanding with a foam pad grit pad. this gets rid of any unwanted residue left over from any other paint fluid etc. Then use 'etch primer' and then top coat. Take your time and let the primer go off fully before you top coat
just about to do a spare master cylinder on my 900s Diversion. as its a spare i can have a crack see how it comes apart.. took it mostly all apart but the piston will not come out.. so not sure if i can just pull it hard and it will pop out or there is something else stopping it from coming out!?
There is normally a circlip under the rubber, which holds the rod in position. Once this is removed the piston will come out. If you have already done this and it still won't come out, don't worry. First try hitting the end of the cylinder down onto your bench (make sure the bench is wood or something softer than the cylinder) If this won't work, immerse the complete cylinder into an engine cleaner (parts washer fluid) and leave it for a few days. Again tap it onto the bench sharply. It will come apart. Make sure to get a good quality rebuild kit, and give the walls of the cylinder a really good clean and inspection. Let me know how you get on.
@@RestorationBikerHi, thanks for the quick reply! 😊 Yes, the circlip was removed, but I think it’s just the old seal catching inside the cylinder. It feels like it needs a really hard pull-the piston seems completely stuck. Since I’ve never taken one apart before, I came across your video, and even though yours is the 600, the parts look identical. I’ll soak it as you suggested and give it another try over the weekend. This is just a spare caliper I had lying around so I could see how they come apart. My main bike, sadly, has been sitting out front in all weather. The front brake pistons are very stuck-poor thing! It’s been out there for five years now because of the ULEZ rules, as it doesn’t qualify. 😞 It’s sentimental to me and my son, so I can’t bring myself to sell it. I rode it for seven years before the ULEZ hit and took great care of it-changed the oil every 1,000 miles with filters and kept it in good shape. It’s a 2002 Diversion 900S in red, only 28k miles! All it ever needed was fuel and regular servicing. It’s only had two sets of tires, as I mainly used it for commuting and the occasional nice-weather ride. I recently sorted out the rear caliper, which was stuck. We replaced the seals, and now it’s like new. I used to have two spares and almost finished one, but they took up too much room in the garden, so I had to sell them. Luckily, I kept a few parts-wheels, forks, a clock reset button, rear shock, downpipes, and some other odds and ends. The battery died during the last cold snap and wouldn’t hold a charge, but I replaced it with a good, affordable one from Powerline for just £35 (compared to £90+ elsewhere!). Now the bike starts on the button and is much happier.
@@rs2klee Hi, yes that is exactly how they end up. You feel that you want to pull it hard and it will come out. Or drift it from the other side etc. But of course you can't. If you let it soak you will be amazed the difference once you get some fluid in there to loosen off the corrosion. Just leave it submerged for a few days or a week. That will do it. It is the same with calipers. But I do have a slide tool which can be used to get the pistons out. But, man they can be really stuck, and I mean STUCK!! But once again I just leave them to soak and they normally let go in the end. It is very satisfying when you get the brakes all working as they should. I hate binding brakes.
Yes, once the piston has moved a small amount it closes off the large hole. This hole is how fluid enters the system once the lever is released. Hope this helps, good question.
@@RestorationBiker thank you . I'm currently working on a xj900 diversion and have been having issues with pressure loss on the front brakes after doing a full rebuild of the callipers and upgrade from rubber lines to braided . my original master cylinder was far to gone to be saved and bought a new one and had noticed that the silver piston that can be seen through the lager hole wasn't fully sealing off the hole when i released the leaver and wondered if that could be the issue or not
Excellent how to on servicing the master cylinder. I took mine apart 6 months ago and had to watch your great vid on how it goes back together Thanks 😊 👍
Hi, glad you liked it. Many thanks
that was very interesting . i never saw one off these adjustble brakes . thanks for sharing .
Glad you enjoyed it. Nice to hear from you again. Take care.
Thank you, a really helpfull post.
Glad it was helpful! Makes it worthwhile making them.
Beautiful job. What did you use to work on the brake fluid lid (cover) with the Yamaha writing on it? Mine looks awful and I'm afraid of sanding it with anything because I don't want to accidentally remove the writing.
I usually use paint stripper when I am doing these kind of jobs. then a light sanding with a foam pad grit pad. this gets rid of any unwanted residue left over from any other paint fluid etc. Then use 'etch primer' and then top coat. Take your time and let the primer go off fully before you top coat
just about to do a spare master cylinder on my 900s Diversion. as its a spare i can have a crack see how it comes apart.. took it mostly all apart but the piston will not come out.. so not sure if i can just pull it hard and it will pop out or there is something else stopping it from coming out!?
There is normally a circlip under the rubber, which holds the rod in position. Once this is removed the piston will come out. If you have already done this and it still won't come out, don't worry. First try hitting the end of the cylinder down onto your bench (make sure the bench is wood or something softer than the cylinder) If this won't work, immerse the complete cylinder into an engine cleaner (parts washer fluid) and leave it for a few days. Again tap it onto the bench sharply. It will come apart. Make sure to get a good quality rebuild kit, and give the walls of the cylinder a really good clean and inspection. Let me know how you get on.
@@RestorationBikerHi, thanks for the quick reply! 😊 Yes, the circlip was removed, but I think it’s just the old seal catching inside the cylinder. It feels like it needs a really hard pull-the piston seems completely stuck. Since I’ve never taken one apart before, I came across your video, and even though yours is the 600, the parts look identical. I’ll soak it as you suggested and give it another try over the weekend.
This is just a spare caliper I had lying around so I could see how they come apart. My main bike, sadly, has been sitting out front in all weather. The front brake pistons are very stuck-poor thing! It’s been out there for five years now because of the ULEZ rules, as it doesn’t qualify. 😞 It’s sentimental to me and my son, so I can’t bring myself to sell it.
I rode it for seven years before the ULEZ hit and took great care of it-changed the oil every 1,000 miles with filters and kept it in good shape. It’s a 2002 Diversion 900S in red, only 28k miles! All it ever needed was fuel and regular servicing. It’s only had two sets of tires, as I mainly used it for commuting and the occasional nice-weather ride.
I recently sorted out the rear caliper, which was stuck. We replaced the seals, and now it’s like new. I used to have two spares and almost finished one, but they took up too much room in the garden, so I had to sell them. Luckily, I kept a few parts-wheels, forks, a clock reset button, rear shock, downpipes, and some other odds and ends.
The battery died during the last cold snap and wouldn’t hold a charge, but I replaced it with a good, affordable one from Powerline for just £35 (compared to £90+ elsewhere!). Now the bike starts on the button and is much happier.
@@rs2klee Hi, yes that is exactly how they end up. You feel that you want to pull it hard and it will come out. Or drift it from the other side etc. But of course you can't. If you let it soak you will be amazed the difference once you get some fluid in there to loosen off the corrosion. Just leave it submerged for a few days or a week. That will do it. It is the same with calipers. But I do have a slide tool which can be used to get the pistons out. But, man they can be really stuck, and I mean STUCK!! But once again I just leave them to soak and they normally let go in the end. It is very satisfying when you get the brakes all working as they should. I hate binding brakes.
this may be a stupid question but is the piston inside supposed to completely close off the bigger hole inside of the master cylinder ?
Yes, once the piston has moved a small amount it closes off the large hole. This hole is how fluid enters the system once the lever is released. Hope this helps, good question.
@@RestorationBiker thank you . I'm currently working on a xj900 diversion and have been having issues with pressure loss on the front brakes after doing a full rebuild of the callipers and upgrade from rubber lines to braided . my original master cylinder was far to gone to be saved and bought a new one and had noticed that the silver piston that can be seen through the lager hole wasn't fully sealing off the hole when i released the leaver and wondered if that could be the issue or not
Nice one might have a crack at my brakes, they are in a lot worse state than these but we'll see..
Glad you found it helpful. Don't forget if you do your brakes and you get a problem, send me a message and I will see if I can help.