Front Master Cylinder Woes

Righty...... has anyone rebuilt a front master cylinder? I've disassembled mine (2002 bike) and parts resemble this exactly

However what turned up was



However looking at part diagrams from 1997 right through to 2002 it always lists the SAME rebuild kit Honda part number (45530-MY5-731) yet varies to whether it includes the 2nd spring and exposed spindle (45526-MY5-731 & 45525-MY5-G31).

Are the ones I received just updated versions of the internals I removed and how can the same part number contain different contents over the years?

Dan

I don't know the answer to this, other than to say, the master cylinder rebuilt kit I got (admittedly some time ago) did *not* have the extra spring and rod included. I used my existing ones.

Interestingly this isn't always possible as the spring can corrode if water has got under the seal...

Just spoke to the guy at my dealership who was equally baffled and only explanation was that it is a superseded part (which I had ordered from Wemoto) and the internals and picture on their site were an older version of it.

As it happens he said that in a dusty corner of the parts warehouse they actually had one of the older kits sitting around........ which is now mine. He also said he wouldn't be overly keen about putting in the revised internals after removing different ones.

Might also separately order the 2nd spring and plunger for good measure.

EDIT: may order the £4 spring but at £13 for the plunger rod - they can f*ck right off!

Definitely get the second spring, they love to rust. The last coil snaps off and it causes the brake lever to bounce slightly (causing the brake light to flicker on and off).
I slopped a load of red rubber grease in there when I replaced it last time, hopefully it will last a while longer!

thanks I've ordered the spring but decided to leave the plunger as it seems fine.

I'm having the same weird problem, Please could I have a link to the spring? mine is rusty.

This is the outer spring: http://zsf-motorrad.de/product/11497
I'm going to maintenance another Brembo master cylinder soon. Unfortunately there are no aftermarket parts for the Brembo caliper available in Germany, so I have to go for the expensive Honda parts. In my opinion it is necessary to renew all inner parts. The worn sealings are causing the rust.

Yeah that's how mine looked, full of rust. The screen inside the reservoir had some holes bunged up with gunk also, I last changed the fluid 2 years ago and the lever has been getting spongey.