Master cylinder rebuild

[Padre4art]

Hi . . . I am about to embark on the adventure of a total brake rebuild. Everything on the bike dates to 1978.

One question: how exactly do you remove the electrical wire from the front master? Manual doesn't help.

Thanks!

Art

[IanDMacDonald]

Howdy- You will find a hole that you can stick a screwdriver into. Push lightly, and pull on the connector. It's a clip that holds it in. Be careful, as they're prone to break. They're available OEM, so if it breaks, don't sweat it.

[Padre4art]

Snap ring pliers

Thank you for your response on the electrical connection. I'm also uncertain as to where to find a set of snap ring pliers that will work on both master cylinders to remove the snap ring?

[bikerphil]

I use a couple of small picks to remove the snap rings but it is nice to have the proper tool...

https://www.mikesxs.net/yamaha-xs650...ng-pliers.html

[Padre4art]

Caliper rebuild

Thank you . . . Ordered the circlip pliers.

Q: the manuals say 'leave caliper rebuilding to the professionals.'

What do you suggest?

Thanks

Art

[Radioguylogs]

Don't worry

Art:

Rebuilding the calipers is just a matter of taking a few parts apart, cleaning them, and reassembling. There are no difficult workmanship issues.

The only hard part is getting the piston out to get started.

The usual methods to get the piston out include:
(1) Use the rear master cylinder to get all the pistons out
(2) Use a grease gun
(3) Use compressed air and have a rag in place to catch the 2lb bullet.

[mcmotohistory]

I'm using a brand new front master cyclinder that at got at Mikes XS that works on xs650 and also our 1100. It made a big difference and really was not expensive. It was also a cosmetic improvement over the old clear plastic one.

[IMG][/IMG]