front master cylinder rebuild

Discussion in 'Other Service and Maintenance' started by C A C, Feb 27, 2012.

  1. C A C

    C A C New Member

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    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
     
  2. Rubyred

    Rubyred Senior Member

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  3. fin_676

    fin_676 Well-Known Member Staff Member Moderator Contributor

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    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

    Brian
     
  4. HDDon

    HDDon Experienced Member Contributor Retired Moderators

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  5. C A C

    C A C New Member

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    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.
     
  6. Dr. Dolittle

    Dr. Dolittle Experienced Member Staff Member Moderator Contributor

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    You're never far from the best helpers in the world as long as you've got internet with this site bookmarked!
     
  7. Jack Klarich

    Jack Klarich Expert Member Contributor

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    Last edited: Feb 27, 2012