Does anybody have.....

[Suckerpunch]

Does anybody have a real clean crisp picture of how a master cylinder rebuld kit fits back together?

Im having a problem with online guides being to fuzzy. The main problem is with the spring and the cup. I think they are on backwards.

1980 xs1100sg

[crazy steve]

I just did mine... no pics, but I can tell you how it fits.

The return spring is tapered, and has a metal 'cap' on the small end. The big end goes into the bore first. The rubber cup goes in next, with the open end towards the spring; the flat side is against the plunger. Plunger next, then the c-clip, then the seal/boot.

One thing to check before assembly is to make sure the plunger moves freely in the bore. It takes very little corrosion to cause this to hang up, so I've honed the bore. A piece of wood dowling with a slit cut in it and some folded sandpaper (400-600 grit) works well.

'78E original owner

[Suckerpunch]

ok, you have found my problem! I had the spring and cap backwards.

Thanks for the very clear post.

I just did mine... no pics, but I can tell you how it fits.

The return spring is tapered, and has a metal 'cap' on the small end. The big end goes into the bore first. The rubber cup goes in next, with the open end towards the spring; the flat side is against the plunger. Plunger next, then the c-clip, then the seal/boot.

One thing to check before assembly is to make sure the plunger moves freely in the bore. It takes very little corrosion to cause this to hang up, so I've honed the bore. A piece of wood dowling with a slit cut in it and some folded sandpaper (400-600 grit) works well.

'78E original owner

[Suckerpunch]

I do have a flat washer I think goes in between the plunger and c-clip?

I just did mine... no pics, but I can tell you how it fits.

The return spring is tapered, and has a metal 'cap' on the small end. The big end goes into the bore first. The rubber cup goes in next, with the open end towards the spring; the flat side is against the plunger. Plunger next, then the c-clip, then the seal/boot.

One thing to check before assembly is to make sure the plunger moves freely in the bore. It takes very little corrosion to cause this to hang up, so I've honed the bore. A piece of wood dowling with a slit cut in it and some folded sandpaper (400-600 grit) works well.

'78E original owner

[WMarshy]

Not sure if your talkin about the rear or front master... but on the rear master there is a thin flat washer under the seal. It goes, spring, 'cap', seal, washer, piston body. Place them in the bore, lube the bore and seal with some fluid so they slide in nice, then there is a washer that has a slot in it, slip that around the piston body once its in the bore and then put on the circlip.

[crazy steve]

I do have a flat washer I think goes in between the plunger and c-clip?

You're right... I forgot about that.

'78E original owner

[Suckerpunch]

sorry, front master.

Not sure if your talkin about the rear or front master... but on the rear master there is a thin flat washer under the seal. It goes, spring, 'cap', seal, washer, piston body. Place them in the bore, lube the bore and seal with some fluid so they slide in nice, then there is a washer that has a slot in it, slip that around the piston body once its in the bore and then put on the circlip.

[Suckerpunch]

It was pointed out but, I assume you too are talking about the front master?

You're right... I forgot about that.

'78E original owner

[crazy steve]

It was pointed out but, I assume you too are talking about the front master?

Yes...
The rear is harder to 'mis-assemble', but Marshy covered that. The main thing to remember on any hydraulic system is the 'open' or 'flared' side of the seal/cup goes towards the pressure side of the system.

'78E original owner

[FJ111200]

Tom on the UK site has just posted up some clear drawings of the XS parts. Looks like it's from Holland or Belgium.
http://www.benefiscal.co.uk/forum/in...5.msg69481#new