Zero_Deal
10-04-2011, 11:26 AM
Hi guys,
New here (intro: http://nswroadandtrackbikes.com/forums/showthread.php?18331-Hellooooo-to-all...-and-tempest.&p=328061#post328061)
but i recently did some work on the bike and thought i'd share as as i was at wits ends until i found the solution... hopefully it'll help save someone some pain.
I had some majors issues with the front anchors on the 076RR. The lever was pulling all the way to the clip on when enough pressure was applied.
Checked and re-check entire system, did multiple bleeds... no external leak and no air in the system.... so as a last resort, bit the bullet and decided to service the MC and after doing this, the brakes are ROCK SOLID!!!
Tools required: Small/short Phillips head and large flat head screwdrives, 12mm and 14mm and driver, torque wrench, 8mm spanner, circlip pliers, lost of rags/paper towels.
Parts required:
Front Master Cylinder Service kit: Part number 45530-MFJ-D01
Fresh Brake fluid
silicone grease
Difficulty out of 10: 4/10 (oil change =1.5)
First up, you need to completely bleed your brakes of all the fluid. (there are already plenty of DIYs for this so i will not cover here)
Next you gotta remove the kill switch from the bar, and remove the brake switch from under the MC.
[/URL]http://img200.imageshack.us/img200/301/69927529.jpg (http://img200.imageshack.us/img200/301/69927529.jpg)
now remove the lever, give it and the bolt/screw a good clean and set it aside.
http://img251.imageshack.us/img251/1867/31598896.jpg (http://img251.imageshack.us/img251/1867/31598896.jpg)
http://img192.imageshack.us/img192/4092/70901000.jpg (http://img192.imageshack.us/img192/4092/70901000.jpg)
Next, loosen and remove the banjo from the MC and lines. make sure you have plenty of rags to catch any drips.
http://img852.imageshack.us/img852/63/44902468.jpg (http://img852.imageshack.us/img852/63/44902468.jpg)
Now you will see the push rod and external boot, just pull the boot off and the push rod will come with it. pull out the push rod from the boot and set it aside. The push rod will be re-used.
http://img840.imageshack.us/img840/1724/80055869.jpg (http://img840.imageshack.us/img840/1724/80055869.jpg)
http://img853.imageshack.us/img853/9450/24858029.jpg (http://img853.imageshack.us/img853/9450/24858029.jpg)
http://img35.imageshack.us/img35/504/63724388.jpg (http://img35.imageshack.us/img35/504/63724388.jpg)
Now loosen and remove the MC bracket from the bar, now you can remove the MC and put it on a bench to work on it.
http://img705.imageshack.us/img705/1663/97016194.jpg (http://img705.imageshack.us/img705/1663/97016194.jpg)
Now take the MC in one hand, use that thumb in that hand to slightly compress the cylinder and with your other hand use the cir-clip pliers to remove the cir-clip. REMEMBER to keep pressure on the cylinder and slowly let it out once the cir-clip is removed or else parts will be sent flying across the room.
Once the old MC parts come out, lay it on the bench as it comes out so you know the exact orientation of parts as they come out. Pics in the repair manual have the sequence of parts in the wrong order.... now get the new parts and check that you have all the following:
http://img146.imageshack.us/img146/3764/45803555.jpg (http://img146.imageshack.us/img146/3764/45803555.jpg)
Now lay it out in the same order as the old item:
(top = New parts)
http://img35.imageshack.us/img35/5449/81765297.jpg (http://img35.imageshack.us/img35/5449/81765297.jpg)
Now inspect and clean the internal parts of the MC with fresh clean fluid. I used a large syringe filled with new fluid and used it to squirt and flush the inside of the MC. If all is good and no scratches on the inner walls, then it will be good to go. Set it aside for now.
[URL="http://img163.imageshack.us/img163/5471/15817435.jpg"]http://img163.imageshack.us/img163/5471/15817435.jpg (http://img163.imageshack.us/img163/5471/15817435.jpg)
Now comes the tricky bit. You have to now pull the 2 rubber seals over the piston. the smaller one is ok, but the larger more stiffer one was a real pain. Use heaps of fresh fluid as a lube and work slowly ensuring not to damage the seals. REMEMBER the correct orientation of the seals.
This is where my old piston failed. The inner seal was worn and was letting fluid pass around the seal when enough pressure was applied. I guess like all rubber seals, it will eventually get too worn and past it's service life and will need replacing.
http://img855.imageshack.us/img855/6202/64742905.jpg (http://img855.imageshack.us/img855/6202/64742905.jpg)
Once you have the seals in place on the piston, squirt a bit of fluid all over the piston and the walls of the MC. Take the new piston (and other parts) and insert into the MC. Use the reverse method of removing to install the piston and cir-clip. Once installed, use a small screwdriver to push the cir-clip to ensure it is seated correctly.
http://img5.imageshack.us/img5/1226/97258902.jpg (http://img5.imageshack.us/img5/1226/97258902.jpg)
Now that you have the piston installed, press it a few time to check that it glides smoothly.
Now re-install everything and bleed the calipers and the MC. I bled the entire system 5 times (but it was solid after the second bleed.. i just felt like doing the extra bleeds for piece of mind)
Remember to use new crush washer at the banjos and torque up correctly, use silicone grease in the ball joint and on the pivot surface of the brake lever.
Check for leaks and away you go... ROCK SOLID BRAKE LEVER.
hope this helps others with the same issue i had...
Cheers.
New here (intro: http://nswroadandtrackbikes.com/forums/showthread.php?18331-Hellooooo-to-all...-and-tempest.&p=328061#post328061)
but i recently did some work on the bike and thought i'd share as as i was at wits ends until i found the solution... hopefully it'll help save someone some pain.
I had some majors issues with the front anchors on the 076RR. The lever was pulling all the way to the clip on when enough pressure was applied.
Checked and re-check entire system, did multiple bleeds... no external leak and no air in the system.... so as a last resort, bit the bullet and decided to service the MC and after doing this, the brakes are ROCK SOLID!!!
Tools required: Small/short Phillips head and large flat head screwdrives, 12mm and 14mm and driver, torque wrench, 8mm spanner, circlip pliers, lost of rags/paper towels.
Parts required:
Front Master Cylinder Service kit: Part number 45530-MFJ-D01
Fresh Brake fluid
silicone grease
Difficulty out of 10: 4/10 (oil change =1.5)
First up, you need to completely bleed your brakes of all the fluid. (there are already plenty of DIYs for this so i will not cover here)
Next you gotta remove the kill switch from the bar, and remove the brake switch from under the MC.
[/URL]http://img200.imageshack.us/img200/301/69927529.jpg (http://img200.imageshack.us/img200/301/69927529.jpg)
now remove the lever, give it and the bolt/screw a good clean and set it aside.
http://img251.imageshack.us/img251/1867/31598896.jpg (http://img251.imageshack.us/img251/1867/31598896.jpg)
http://img192.imageshack.us/img192/4092/70901000.jpg (http://img192.imageshack.us/img192/4092/70901000.jpg)
Next, loosen and remove the banjo from the MC and lines. make sure you have plenty of rags to catch any drips.
http://img852.imageshack.us/img852/63/44902468.jpg (http://img852.imageshack.us/img852/63/44902468.jpg)
Now you will see the push rod and external boot, just pull the boot off and the push rod will come with it. pull out the push rod from the boot and set it aside. The push rod will be re-used.
http://img840.imageshack.us/img840/1724/80055869.jpg (http://img840.imageshack.us/img840/1724/80055869.jpg)
http://img853.imageshack.us/img853/9450/24858029.jpg (http://img853.imageshack.us/img853/9450/24858029.jpg)
http://img35.imageshack.us/img35/504/63724388.jpg (http://img35.imageshack.us/img35/504/63724388.jpg)
Now loosen and remove the MC bracket from the bar, now you can remove the MC and put it on a bench to work on it.
http://img705.imageshack.us/img705/1663/97016194.jpg (http://img705.imageshack.us/img705/1663/97016194.jpg)
Now take the MC in one hand, use that thumb in that hand to slightly compress the cylinder and with your other hand use the cir-clip pliers to remove the cir-clip. REMEMBER to keep pressure on the cylinder and slowly let it out once the cir-clip is removed or else parts will be sent flying across the room.
Once the old MC parts come out, lay it on the bench as it comes out so you know the exact orientation of parts as they come out. Pics in the repair manual have the sequence of parts in the wrong order.... now get the new parts and check that you have all the following:
http://img146.imageshack.us/img146/3764/45803555.jpg (http://img146.imageshack.us/img146/3764/45803555.jpg)
Now lay it out in the same order as the old item:
(top = New parts)
http://img35.imageshack.us/img35/5449/81765297.jpg (http://img35.imageshack.us/img35/5449/81765297.jpg)
Now inspect and clean the internal parts of the MC with fresh clean fluid. I used a large syringe filled with new fluid and used it to squirt and flush the inside of the MC. If all is good and no scratches on the inner walls, then it will be good to go. Set it aside for now.
[URL="http://img163.imageshack.us/img163/5471/15817435.jpg"]http://img163.imageshack.us/img163/5471/15817435.jpg (http://img163.imageshack.us/img163/5471/15817435.jpg)
Now comes the tricky bit. You have to now pull the 2 rubber seals over the piston. the smaller one is ok, but the larger more stiffer one was a real pain. Use heaps of fresh fluid as a lube and work slowly ensuring not to damage the seals. REMEMBER the correct orientation of the seals.
This is where my old piston failed. The inner seal was worn and was letting fluid pass around the seal when enough pressure was applied. I guess like all rubber seals, it will eventually get too worn and past it's service life and will need replacing.
http://img855.imageshack.us/img855/6202/64742905.jpg (http://img855.imageshack.us/img855/6202/64742905.jpg)
Once you have the seals in place on the piston, squirt a bit of fluid all over the piston and the walls of the MC. Take the new piston (and other parts) and insert into the MC. Use the reverse method of removing to install the piston and cir-clip. Once installed, use a small screwdriver to push the cir-clip to ensure it is seated correctly.
http://img5.imageshack.us/img5/1226/97258902.jpg (http://img5.imageshack.us/img5/1226/97258902.jpg)
Now that you have the piston installed, press it a few time to check that it glides smoothly.
Now re-install everything and bleed the calipers and the MC. I bled the entire system 5 times (but it was solid after the second bleed.. i just felt like doing the extra bleeds for piece of mind)
Remember to use new crush washer at the banjos and torque up correctly, use silicone grease in the ball joint and on the pivot surface of the brake lever.
Check for leaks and away you go... ROCK SOLID BRAKE LEVER.
hope this helps others with the same issue i had...
Cheers.