Step 1: Front Brake Master Cylinder Removal
In order to rebuild the master cylinder the master cylinder will need to be removed from the bike. We started the job by removing the brake fluid from the system. During the master cylinder removal process protect any painted surfaces from brake fluid as it may damage the finish. Then after the system was drained we disconnected the brake lines from the master cylinder. It is best to remove the brake lines first as it is very difficult to remove the banjo bolt after the master cylinder has been removed from the clip on. While the master cylinder is installed on the clip on we also remove the lever. Then using an 8mm socket we remove the master cylinder from the clip on.

Step 2: Master Cylinder Disassembly
Once the master cylinder is removed the hard part begins. We start breaking down the master cylinder by removing the reservoir and master cylinder fill tube. Under the cover for the fill tube connector there is a snap ring (circlip) that needs to be removed in order to replace the connector. Even if the connector is not damaged it is best to remove the nipple as it allows for a complete cleaning of the inside areas of the master cylinder.

Step 3: Master Cylinder Piston Removal
The hardest portion of this project is the removal of the retainer snap ring for the master cylinder piston. First the rubber dust cover will need to be removed in order to reveal the snap ring. It tends to be very difficult to remove the snap ring as the amount of space to work in is very limited. Once the snap ring is removed the piston can be pulled out.

Step 4: Cleaning the Master Cylinder
Now it is time to clean the master cylinder and its components. Using a brake cleaning solvent we spray down the master cylinder and all the components inside and out. Using a soft non-abrasive plastic bristle brush to scrub the master cylinder and it’s components to insure that we remove any heavy dirt deposits. Then using air nozzle we remove any residual cleaner and dirt deposits from the master cylinder and components.

Step 5: Rebuilding of the master cylinder
In reverse order we rebuild the master cylinder taking care not to damage any of the rubber components.