Hello, John Talley here with partzilla.com.
Today I'm going to show you how to rebuild the front brake master cylinder on our 2008
Honda CBR 600 RR.
Honda has this nice little kit put together with all the internals.
So, let's start off by just getting all the brake fluid drained out of it and I'll show
you how to get it rebuilt.
Alright guys, let's go through some of the tools you're going to need to get this job
done.
Just a standard flat-blade screwdriver, 3/8 ratchet and a couple of different sockets--
I believe that's a 10 and an 8.
A 12mm, just open end wrench, and this little guy comes in handy.
It's just a 90 degree Phillips.
A punch pick tool, and then the most specific tool that you're going to need is a set of
circlip pliers and just a regular set of needlenose pliers.
All of this and that'll be all you'll need to get it done.
Before we start pulling out the fluid we need to go ahead and get the cap pulled off.
To do that they've got a little bracket on the backside.
Why is it there?
I'm not entirely certain but I guess it keeps it from lifting off if you somehow unscrewed
it-- a redundancy.
But I wasn't in on that design meeting.
Alright, let's go ahead and extract the fluid out of there.
That ought to do it.
Alright, we can pretty much take off that entire assembly.
What we need to do is let's start off with the handle.
That's a 10mm bolt on the bottom.
So more or less a lock nut.
Once you get it off it's just a flat blade to get the pivot pin out.
Alright, next let's go ahead and get the switch disconnected.
It's just a switch, so there's no polarity involved there.
Next, let's go for the main line heading down to the calipers.
When you disconnect this you want to make sure no brake fluid gets on the fairing.
So have a paper towel ready to go in case any drips on there, which is definitely going
to happen.
Yep, there it goes.
When you're moving this banjo bolt, there's going to be two crush washers.
You need to keep up with both of those: one on the bottom, one on the top.
Now, you should just be able to get these two 8mms on the backside and the assembly
should come off.
Now what conditions would bring about you needing to rebuild this?
If you've got a real spongy kind of feel in the brake lever-- not really activating the
front brakes properly.
You've bled it and you're sure there's no air in the system.
Chances are the seals that provide that pressure are probably worn out and there she is.
Alright, let's carry her over to the teardown table and we'll get it pulled apart.
Alright guys, got it over here on the bench and now we just need to pull it apart.
Basically it's all held in by this one little circlip on the outside.
So let's get that rubber boot out of the way and get this circlip out and then all of this
stuff that you see in this kit will be crammed inside here.
So we'll pull all of the old stuff out and get the new stuff in.
Bore looks good, nice and smooth.
Let's get a little fluid on our new seals, and let's get her put back together.
Check to see how good your dexterity is.
Alright guys, she's all in there now.
So, let's get it mounted back on the machine.
Pretty much just the exact reverse of what we did to take it apart.
Go on and get your main hose down below put on.
Don't forget your crush washers on the bottom, and one on the top.
Next, let's go ahead and get that brake lever switch hooked up.
Remember these are not-- polarity doesn't matter.
Non-specific.
They don't care.
Alright, after that let's clean up our pin right here and put some new grease on it and
get our lever in place.
And that pinch bolt on the bottom.
Alright guys, well that pretty much wraps it up.
the only thing we have to do now is just refill the system with some DOT4 brake fluid and
then bleed the system.
If you would, reference our video to show you how to get that done.
Listen, if you need any of the parts that we used, come see us at partzilla.com and
we can get you taken care of.
If you have any comments or questions, leave them in the section below and I'll do my best
to answer it.
And until next time we just want to say thanks for watching.