Rear Brake Master Cylinder

[Elielrosario]

Hey guys, I'm having a little trouble installing the piston set ('77 GS750). I've looked at the exploded views (and search here) but can't figure out the if the piece with the brass nipple goes nipple-up or nipple-down. Also not sure if the spring goes with the thinner end going up or down?

[btbarb]

Assembly pic

Hey guys, I'm having a little trouble installing the piston set ('77 GS750). I've looked at the exploded views (and search here) but can't figure out the if the piece with the brass nipple goes nipple-up or nipple-down. Also not sure if the spring goes with the thinner end going up or down?

This master cyl looks similar, check this assembly pic from Nessim on post #2 of this thread --> Rear Master Cyl Assembly Pic

[Elielrosario]

Awesome! That helps a lot, I'll try it out today! (Praying brakes wont stick/drag anymore)

Thanks a bunch.

[Kiwi Canuck]

I just rebuilt mine last night so it's fresh in my mind.

The little brass tit goes into the end of the spring, and will be pointing up when installed on the bike.
So from the top, you have the first seal (lower right in the picture) spring, then the piece with the brass tit, then the shaft.
The concaved end to the bottom which mates with the domed end of the actuation rod.

http://www.boulevardsuzuki.com/fiche_section_detail.asp?section=95661&category=Motorcycles&make=SUZUKI&year=1980&fveh=2150

Hope this helps.

[Agemax]

also make sure the tiny return hole in the M/C is clear. it is very tiny and located where the reservoir inlet is on the M/C. if this is blocked it will cause the brakes to stick on or not release properly

[Elielrosario]

Wait... I feel like I'm getting two different instructions here:
1) the image that BTBARB shared, showing the order; and
2)Kiwi Canuck's assembly, which seems to be inverted (when compared to the images provided by Nessim btbarb's link)

Or am I just reading it wrong (it's been a long day)?

[koolaid_kid]

They look the same to me. let me walk you through the Boulevard Suzuki assembly:
At the top is the piece that BTBARB shows attached to the right side of the spring.
Just below the spring is part #2, which BS shows attached to the spring but BT shows just to the left of the spring but unattached and in two pieces.
First is the rubber seal, then a plunger. BS shows it as all one piece.

[Elielrosario]

Gotcha. The boulevard Suzuki assembly link doesn't on my side. But I'm pretty i understand (again, long day).

I have a job interview after my day job (today), so hopefully I'll make it home in time to change it out and test ride.

Thanks again

[Elielrosario]

Tried it but no fluid is going thru at all. Is the brass nipple supposed to have freeplay?

[Kiwi Canuck]

Hold that thought!

I may have steered you wrong, I checked the other pictures and it's different than I described.
I'll go and check again and make sure, and post a picture.

[Kiwi Canuck]

I may have steered you wrong, I checked the other pictures and it's different than I described.
I'll go and check again and make sure, and post a picture.

Ignore my earlier post I did give you the wrong info, the picture link posted by btbarb is correct, my apologies

[Elielrosario]

Thanks. The only other way I haven't tried it is using the same setup except with the nipple up. I had it that way before but with the spring's narrow/flat end facing up, I haven't tried it facing down and nipple piece facing up.

[Kiwi Canuck]

This it



This is the correct order, you must have a blockage somewhere else if you have tried this and it doesn't work.

[Elielrosario]

New parts should be arriving next week, so I guess I'll have to wait until then to see if these are just damaged.
Thanks, I'll update in case someone later has a similar issue.

[Rockman]

Yep, just done mine and exactly as per the picture. Leave the hose off or loose until the M/C has filled up or it will take a while to fill.