Rear master problem

[jwhelan65]

I replaced the rear master on my 700 with a used one but I cannot get it to push fluid, the piston appears to be all the way in so the lever moves but I cant get the piston to release? any suggestions???

 

[chuck hahn]

take it off and turn it upside down and pull the plunger boot back to expose the rod. spray some penetrating oil down the rod and into the banjo bolt hole and gently tyn to work the rod in and out to see if it releases. Did you actually disassemble it and be sure the bore and inner rubber cups are ok??? mat need to be broke down and recleaned..and a tip for cleaning the bore..i used my 45 caliber muzzleloader brass brush in mine with a good dose of hoppes 9

 

[jwhelan65]

Chuck,

I removed the C-clip and the rod and cleaned everything real well. There is not any way to really pull it a part is there?

 

[chuck hahn]

shouldnt be!!! theres only the one cup, the rod with the fixed end cup and the spring!! Look at bike bandit or your favorite exploded view and be sure you put it all back in correctly. May have to just pull that c clip back off and pull it apart and check things out..did you wire wheel the pushrod and get all the crud off?? just seems like maybe something is just a bit out of killter..its a lot easier if i was there looking at it with you...LOL

 

[chuck hahn]

only other thing i can think of is you may have inadvertently put the piston and the cups in facing the wrong way.. the cups may have slid up real nice and smooth but now they are sealed against the bore and the airlock wont let the spring push them back down. may take a real small jewlers screwdriver and CAREFULLY get between the lip of the cup and the bore and release the suction.. hold your hand over the end to catch everything best you can.. Once the vapor lock lets go the spring is gonna want to shoot the parts back out with a bit of force. Look up there with a good flashlight once you get the plunger rod removed and see if you see the flat side of the cup or the dished side..if you see the dished side chances are both are in backwards..

 

[Nessism]

 

[chuck hahn]

there ya go!!! I knew how to explain it but not how to post a pic...thanks ED

 

[Nessism]

there ya go!!! I knew how to explain it but not how to post a pic...thanks ED

http://members.dslextreme.com/users/bikecliff/images/how_to_post_pictures.pdf

 

[jwhelan65]

How do you remove the spring and piston?

 

[chuck hahn]

push them out from the banjo bolt hole with a small phillips screwdriver

 

[jwhelan65]

push them out from the banjo bolt hole with a small phillips screwdriver

Mine is kind of "L" shaped, not sure if it can be done...

 

[chuck hahn]

a thicker plastic zip tie will flex and push it out then..put the knobby end in and work it till,it makes the bend and your home free.

 

[Nessism]

Compressed air in though the outlet may work too.

 

[chuck hahn]

Very slowly though... dont need any air propelled piston missiles!!! just enough "air" to move them out reasonably safe.

 

[almarconi]

You may want to soak the bore in PB blaster overnight. Probably a lot of crud in the bore keeping the piston from coming out.

 

[jwhelan65]

Still no luck, may have to bite the bullet and spend $165.00 for a new one

 

[Nessism]

Still no luck, may have to bite the bullet and spend $165.00 for a new one

What did you try?

 

[jwhelan65]

What did you try?

Soaked it over night in PB Blaster, compressed air did not work could not get it to seal around the banjo bolt opening.

 

[jwhelan65]

A few pics....

 

[Nessism]

Joe,
Get yourself a rubber grommet or similar and use that to seal the air chuck when you blow into the master. Even a few rounds of duct tape may do the job. Don't give up that easily.