Hello, John Talley here with partzilla.com.
Today I want to show you how to rebuild the rear master cylinder on our 2008 Honda CBR
600 RR.
It starts by just draining out the brake fluid, so let me go grab a couple of tools and let's
get started.
Alright, let's go through some of the tools you're going to need to get this project done--
nothing that extreme.
You just need a 8mm, a 12mm, and a 14mm-- just open ended wrenches.
A set of needlenose pliers, 12mm socket, looks like a 5mm Allen, a 90 degree screwdriver
makes life a lot easier, a regular screwdriver, a pick tool, and most importantly you'll need
a set of circlip pliers.
So once you've got all that, we can get it done.
Alright, let's go ahead and get the fluid extracted out of here.
Connect it up.
Let's get off our reservoir cap, or cover as it is.
Go ahead and get it out of there.
Alright, that should get it.
You're going to need to get out of the way first.
A very small cotter pin on the backside.
Break this loose.
Alright, next let's go ahead and take off the main line going to the caliper.
Be careful not to lose your crush washers.
Next, we want to take these off.
Get it off the machine and then we'll remove that reservoir hose.
It'll be a little easier to get a hold of.
Alright, get this reservoir line off.
Alright, now she's off.
Let's head over to the teardown table and get it rebuilt.
Alright, so let's get this thing pulled apart.
First thing is to get this broken loose on the end so we can get that boot out of there.
Get the boot out.
Alright, now tucked up in there is a circlip.
Looks just like this one.
What you're going to want to do is reach up in there, grab it like this, and then compress
it.
When you do that you should be able to shimmy it out of that bore.
There we go.
Keep a little bit of pressure on that spring makes it easier to pull it out.
And that's the whole assembly.
Alright, let's go ahead and get that sprayed out and cleaned out.
Next, you need to go ahead and get our seal put onto this piston.
Yeah these things can be very tricky to get on there.
You want to make sure that it gets on there flat and it doesn't have a folded edge or
anything like that.
So it takes a little bit of manipulation slash patience.
There it goes.
Alright, now she's in there right.
Alright, let's start coating this stuff down with a little bit of brake fluid and see if
we can get her put back together.
Alright, here comes the fun part guys.
We need to push that spring back in far enough.
Get the plate back.
Alright, what we're going to do is just walk this back and get it to pop back in that groove.
There she is.
That little snap you just heard?
That was it going back into the groove.
Alright, next we're going to get our new boot on.
Let's go ahead and get our arm and pinch bolt back on.
Alright, let's go get it back on the machine.
Alright, assembly is just the reverse of what we did earlier.
So let's go ahead and get this hose reconnected.
Get that clamp slid back down into place.
What I didn't mention earlier what are some of the signs that you actually need to rebuild
your master?
One of the most obvious is if you're having trouble getting the brakes bled and they're
just feeling really spongy, that probably means that seal on the inside is starting
to break down and when it does that it loses pressure.
So that's a very good indicator that your master cylinder is in trouble.
Alright let's get your main line high pressure going back to the caliper, put it back on.
That's snugged in place.
Next let's go through the brake lever itself.
Alright there with your washers they actually go on either side of this piece right here.
Last but not least we need to get that cotter pin back into position.
Alright guys, well that pretty much wraps this one up.
All we have left now is just to refill the system and then bleed it.
And if you would reference our video and I'll show you how to get that done.
Well listen if you need any of the products that we used in this repair, come see us at
partzilla.com and we can get you taken care of.
If you have any questions or comments just leave them in the section below and I'll do
my best to answer them.
Until next time, we just want to say thanks for watching.