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front master cylinder rebuild

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Old Feb 27th, 2012, 03:58 PM     #1
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front master cylinder rebuild

Can anyone direct me to a diagram or instructions on rebuilding the front master cylinder on my 2004 sportster 1200 custom? I need to rebuild my master cylinder, but don't really know what to do.

Thanks
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Old Feb 27th, 2012, 04:21 PM     #2
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Re: front master cylinder rebuild

Ronnie's Harley-Davidson's 2004 Harley Davidson Street Bike SPORTSTER® XL 1200R (CL) Parts List
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Old Feb 27th, 2012, 04:41 PM     #3
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Re: front master cylinder rebuild

I couldn't find anything in the self help area on doing a master cylinder rebuild however it is not a difficult task
drain the system and remove the brake hose
loosen the bolts holding the master cylinder in place and slide gently away from the switches (helps prevent damage to the brake light switch)
fully remove the bolts and remove the master cylinder from the bike
turn the master cylinder over and remove the clip from the brake leaver pin push the pin out and remove the brake leaver
place the master cylinder on workbench with the brake hose hole up put a suitable blunt end rod into the hole till it rests on the piston inside and tap with a hammer
piston seals and spring should drop out of the other end take note of the exact order and orientation of all the parts
clean the inner bore a piece of round dowel with lint free cloth round it works for me
reassembly is the reverse order of disassembly ensure you take care when refitting the master cylinder that the heel on the brake leaver does not damage the brake light switch which is in the switch housing

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Old Feb 27th, 2012, 05:16 PM     #4
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Re: front master cylinder rebuild

Quote: Originally Posted by C A C View Post
Can anyone direct me to a diagram or instructions on rebuilding the front master cylinder on my 2004 sportster 1200 custom? I need to rebuild my master cylinder, but don't really know what to do.

Thanks
All these kits come with instructions. Harley Parts | Aftermarket Harley Davidson Motorcycle and Custom Parts and Accessories | Debrix Cycles - www.debrix.com
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Old Feb 27th, 2012, 07:21 PM     #5
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Re: front master cylinder rebuild

thanks for the input everyone! it doesn't sound like a difficult task, but, having never done it before, i just wanted some input. Thank you.
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Old Feb 27th, 2012, 07:25 PM     #6
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Re: front master cylinder rebuild

You're never far from the best helpers in the world as long as you've got internet with this site bookmarked!
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Old Feb 27th, 2012, 08:14 PM     #7
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Re: front master cylinder rebuild

If rebuild your master with a kit tryhttp://compare.ebay.com/like/400220822643?var=lv&ltyp=AllFixedPriceItemTypes&va r=sbar this on the rubber cups This is the best assembly lube for brake parts I have used Amazon.com: NAPA Sil-Glyde Silicone Lubricating Compound 8 Ounce Tube: Automotive
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