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BRAKES:
--Master Cylinders.
INTRODUCTION:
Okay, here goes:
The older I get, the more important stopping quickly becomes to me. In some ways, it becomes even more important than accelerating quickly. Without a cage to protect you, and out there with all the chattering folks in their 2-ton cars and SUV's and trucks, safety quickly becomes the #1 issue when riding around in the real world---and nothing means "safety" as much as a great set of brakes. So do yourself a favor, and make sure your braking system is all that it can be.......
http://www.xjbikes.com/forums/threads/two-things-that-will-keep-you-alive.113686/
First and foremost, make sure that your stock, original brake system is up to par. Make sure that:
* pads and shoes are within factory specs, and replace if necessary.
* the master cylinder(s) are working properly, and that the fluid is clean and flows freely, without any air bubbles. MAKE SURE THE TINY, MINUSCULE PRESSURE RELIEF PORT IN THE MASTER CYLINDER IS FREE AND CLEAR OR YOUR BRAKES WILL NEVER FULLY RELEASE AND WILL NOT ONLY WEAR QUICKER, BUT THE EXTRA HEAT BUILD-UP WILL:
* warp your rotors.
* wear out your pads.
* dramatically increase your stopping distance.
Brakes work by turning motion into heat, so if your brakes are already heated (due to constant engagement), well........you can guess the rest!
Continuing, please inspect and make sure that:
* the brake hoses are in great condition.
* the calipers are functioning properly, and not stuck or leaking.
* brake rotors are true, within specs as to thickness and runout, and do not exhibit any cracks around the mounting holes nor the outside edges, IF THEY HAVE CRACKS THEY NEED TO BE REPLACED!
http://xjbikes.com/forums/index.php?threads/41403
and
http://xjbikes.com/forums/index.php?threads/41400
To upgrade your brakes, consider:
* if you don't have dual front discs (all North American XJ550 and XJ650 Maxim and Midnight Maxim models), consider doing a conversion to such a set-up.
* install a big-bore master cylinder (as came standard on dual-disc bikes).
* replace stock rubber hoses with stainless-steel braided hoses. This will make a difference you can really feel!
* use higher-friction brake pads and shoes, such as sintered metallic materials. These work better than organic pads once they warm up, but do so at the cost of greatly reducing the life of your rotors and brake drum.
FRONT MASTER CYLINDERS:
mc1) OEM and aftermarket complete front and rear MASTER CYLINDERS, brand new units perfectly replace the originals. Contains lid, diaphram, piston assembly, and lead wires for fluid level switch (on models so equipped). Some master cylinders may NOT include the brake light switch, lever, or mounting hardware........please review the individual applications below for complete information. Lettering and information on the reservoir cover will differ in appearance from your original.
By the way, if you are considering upgrading from one size master cylinder (piston bore diameter) to another, here's some decision parameters that you'll want to consider:
- Using a larger-than-stock bore master cylinder will result in a stiffer handle, and less lever “feel”, since more fluid is being moved with a same movement of the hand lever. It will be “hair-trigger” as far as responsiveness goes. Also note that upgrading to braided steel brake lines will also increase lever stiffness due to the lack of fluid passage “swell” in such brake lines.
- Using a smaller-than-stock bore master cylinder will result in an easier-to-move handle, and with more “feel” (since the lever has to be moved further to displace as much fluid as the original smaller m/c did). HOWEVER, in no case do you want to downsize so much that a full lever stroke does no deliver enough fluid volume to the caliper(s)! Typically, smaller-bore master cylinders can also have a smaller-capacity reservoir, so this can become an issue if using a smaller-than-stock bore master cylinder on a dual-caliper and/or a multi-piston caliper.
More at:
http://www.airheart-brakes.com/pdfs/MasterCylinder_Selection.pdf
and
http://www.vintagebrake.com/mastercylinder.htm
Front Master Cylinders:
HCP3461 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and piston assembly, ready to install. Hand lever, brake light switch, and mounting hardware is not included. Fits all North American XJ550 models. No mounting clamp is included. 13mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. NOTE: the HCP3015 and HCP6277 master cylinders listed below will fit in the same manner and style as this cylinder, but they have the larger-capacity reservoir and bigger piston bore as used on dual-disc brake models. The HCP29622 and HCP3063WO master cylinders are excellent replacements for this original unit.
$ 249.95
HCP29622 Aftermarket complete MASTER CYLINDER ASSEMBLY, brand new aftermarket unit perfectly replaces your original. Comes with cover, diaphram, piston assembly, hand lever, bar clamp and mounting hardware, brake light switch, union bolt, and crush washer----completely ready to install. Fits all North American XJ550 models, although the hand lever that comes with this master cylinder will not have the same bend orientation as original. 12.6mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. NOTE: this aftermarket master cylinder can also be used in place of the original master cylinder on XJ650 Maxim and Midnight Maxim models, as well as all XJ1100 models, but because those are "level" orientation master cylinders, they will place the mirror mounting boss in a different position (and odd angle) compared to the original master cylinders on those models. NOTE: the HCP2667 clutch hand lever is the closest available match in style and finish to the hand lever that comes with this master cylinder. NOTE: this master cylinder has the proper left-hand threads for the stock Yamaha mirrors. This means that any other brand---Kawasaki, Honda, Suzuki, etc.---mirrors will not fit it, since all models besides Yamaha used standard right-hand threads for both the left and right side mirrors). Only Yamaha used left-hand threads on the right side mirror. If you wish to use your stock (or other) Yamaha mirrors with this master cylinder, you can use our mirror adaptors listed below.
$ 129.95
HCP3063WO Aftermarket complete MASTER CYLINDER ASSEMBLY, brand new aftermarket unit perfectly replaces your original. Comes with cover, diaphram, piston assembly, hand lever, mounting hardware, union bolt, and crush washer----completely ready to install. Fits all North American XJ550 models, although the hand lever that comes with this master cylinder will not have the same bend orientation as original. 13mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. NOTE: this aftermarket master cylinder can also be used in place of the original master cylinder on XJ650 Maxim and Midnight Maxim models, as well as all XJ1100 models, but because those are "level" orientation master cylinders, they will place the mirror mounting boss in a different position (and odd angle) compared to the original master cylinders on those models. NOTE: brake light switch is not included with this master cylinder and the proper switch should be ordered separately if needed. NOTE: the HCP2667 clutch hand lever is the closest available match in style and finish to the hand lever that comes with this master cylinder. NOTE: this master cylinder has the proper left-hand threads for the stock Yamaha mirrors. This means that any other brand---Kawasaki, Honda, Suzuki, etc.---mirrors will not fit it, since all models besides Yamaha used standard right-hand threads for both the left and right side mirrors). Only Yamaha used left-hand threads on the right side mirror. If you wish to use your stock (or other) Yamaha mirrors with this master cylinder, you can use our mirror adaptors listed below.
$ 129.95
HCP10141 OEM complete front MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and piston assembly, ready to install. Hand lever, brake light switch, mounting clamp and mounting hardware is not included. Fits 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and all XJ900N, FN, and F models, as well as the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200. Features the 16mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. Cover differs in appearance from original style.
$ 189.95
HCP19388 OEM complete front MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and brake light switch. Hand lever and mounting clamp is not included. Fits all 1992-98 XJ600 Seca II models.
$ 349.95
HCP3014 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, clamp, and piston assembly, ready to install. Hand lever, brake light switch, and mounting hardware are not included, but are available separately. Fits all XJ650 Maxim, XJ650 Midnight Maxim, 1981 XS1100 Midnight Special models, as well as 1983-84 RX50 models, 1987-88, 1990, 1993, and 1995-00 XV535 Virago models, 1981-83 XV750 H/J/K Viragos, 1983 XV750MK Midnight Virago, and 1983 XV920 K/MK Virago models. Mounting clamp is included. 14mm piston bore, horizontally tilted down reservoir orientation, towards-the-bike-centerline fluid outlet port. NOTE: the HCP3018 master cylinder listed below will fit in the same manner and style as this cylinder, but it has a larger-capacity reservoir and piston bore.
$ 339.95
NOTE: a few clarifications about use of the original XJ650 Maxim master cylinders versus the aftermarket cylinders.
There are a couple of differences you need to be aware of:
a) because the stock OEM master cylinder is designed to be used on the stock curvy "buckhorn" style handlebars, the stock master cylinder reservoir is oriented at a "tilted" (from horizontal) mounting angle. This "tilting" allows the mirror to be properly aligned for the use with the stock buckhorn bars and keeps the reservoir in a relatively level position.
b) the aftermarket master cylinder HCP3063WO is designed to mounted on "flat" (or, at least, "flatter") style handlebars, such as the ones found originally on all XJ-series bikes (except the XJ650 Maxim/Midnight Maxim, XJ750 Maxim/Midnight Maxim, or the XJ1100 models.....all of these models used tilted or curvy “buckhorn” style bars). All other models use fairly flat handlebars, and thus the replacement master cylinder will work on those bikes correctly; they leave the mirror mounted in the proper orientation.
c) thus the aftermarket HCP3063WO master cylinder is going to leave the stock mirror tilted at a rather crazy and semi-useless angle when installed on any model that had those curvy, "buckhorn" style bars, and we do not have a stock-style mirror substitute that "solves" this problem. About the only solution we offer is to use the "bar-end" style mirrors, which attach the mirrors to a mounting stem that fits inside the end of the handlebars (which requires modification of the grips by cutting away the rubber on the ends of them, but that is easy enough to do). Of course bar-end mirrors are kind of a unique looks, usually reserved for café- and bobber/rat- themed projects, and may look out of place on a stock “cruiser” style bike.
d) Also, on the XJ650 Maxim and Midnight Maxim models, the fluid outlet port (where the brake hose attaches), is facing "inward", towards the centerline of the bike (when the forks are pointed straight forward). The replacement HCP3063WO master cylinders have their fluid outlet port facing straight forward, and therefore your stock brake line has to be contorted to a rather odd angle to make it reach and fit this forward-facing outlet port. We do have available modified rubber or braided stainless steel brake lines for use of the aftermarket master cylinders on these bikes; their end fitting is rotated by the 90-degrees and extended by an appropriate length to allow it to attach to the aftermarket master cylinders properly.
HCP6277 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and piston assembly, ready to install. Hand lever, brake light switch, and mounting hardware is not included. Fits all XJ650 Turbo, XJ750P (24L), and XJ750P (37H) models. 16mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port.
$ discontinued
HCP3015 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphragm, handlebar mounting clamp (but not the bolts), and piston assembly, ready to install. Hand lever, brake light switch, and handlebar clamp mounting bolts are not included. Fits all XJ550 non-North American models, 1982 XJ650RJ or RJC Seca models, all non-North American XJ650 models, all XJ700 and XJ750-X models, 1984 XJ750RL, all XJ900RK Seca models, and all XJ900RL models. 16mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port.
$ 569.95
HCP24560 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and piston assembly, ready to install. Hand lever, brake light switch, and mounting bracket and hardware are not included, but are available separately. Fits all 1982 XJ750 Maxim and models. This unit has the low brake fluid sensor provision inside the reservoir as used on the 1982 models only. Sensor is not included. Reservoir cover is the later style and does not have the raised, polished “YAMAHA” wording as original. 16mm piston bore, horizontally tilted down reservoir orientation, towards-the-bike-centerline fluid outlet port. NOTE: the HCP1808WO aftermarket master cylinders can be used in place of the original master cylinder on these models, but because those are "level" orientation master cylinders, they will place the mirror mounting boss in a different position (and odd angle) compared to the original master cylinders.
$ 659.95
HCP3018 OEM complete MASTER CYLINDER ASSEMBLY, brand new unit perfectly replaces your original. Comes with cover, diaphram, and piston assembly, ready to install. Hand lever, brake light switch, and mounting bracket and hardware are not included, but are available separately. Fits all 1983 XJ750 Maxim and Midnight Maxim models. NOTE: this unit is identical to, and will also fit and work on the 1982 XJ750 Maxim, but it does not have the low brake fluid sensor inside the reservoir, and thus you will lose that function if this master cylinder is used on a 1982 model. Reservoir cover is the later style and does not have the raised, polished “YAMAHA” wording as original. 16mm piston bore, horizontally tilted down reservoir orientation, towards-the-bike-centerline fluid outlet port. Comes with a glass fluid level sight glass already installed! NOTE: the HCP1808WO aftermarket master cylinders can be used in place of the original master cylinder on these models, but because those are "level" orientation master cylinders, they will place the mirror mounting boss in a different position (and odd angle) compared to the original master cylinders.
$ 599.95
HCP19573 Aftermarket ADAPTER WIRE for low-brake fluid sensor bypass. Since the 1983 master cylinder has no provision for the low-fluid sensor, you need to by-pass the sensor so that the computer is fooled into thinking there is plenty of fluid in the reservoir.
$ 12.95
NOTE: a few clarifications about use of the original XJ750 Maxim master cylinders versus the aftermarket cylinders. There are a couple of differences you need to be aware of:
a) because the stock OEM master cylinder is designed to be used on the stock curvy "buckhorn" style handlebars, the stock master cylinder reservoir is oriented at a "tilted" (from horizontal) mounting angle. This "tilting" allows the mirror to be properly aligned for the use with the stock buckhorn bars and keeps the reservoir in a relatively level position.
b) the aftermarket master cylinder HCP1808WO is designed to mounted on "flat" (or, at least, "flatter") style handlebars, such as the ones found originally on all XJ-series bikes (except the XJ650 Maxim/Midnight Maxim, XJ750 Maxim/Midnight Maxim, or the XJ1100 models.....all of these models used tilted or curvy “buckhorn” style bars). All other models use fairly flat handlebars, and thus the replacement HCP1808WO master cylinder will work on those bikes correctly; they leave the mirror mounted in the proper orientation.
c) thus the aftermarket HCP1808WO master cylinder is going to leave the stock mirror tilted at a rather crazy and semi-useless angle when installed on any model that had those curvy, "buckhorn" style bars, and we do not have a stock-style mirror substitute that "solves" this problem. About the only solution we offer is to use the "bar-end" style mirrors, which attach the mirrors to a mounting stem that fits inside the end of the handlebars (which requires modification of the grips by cutting away the rubber on the ends of them, but that is easy enough to do). Of course bar-end mirrors are kind of a unique looks, usually reserved for café- and bobber/rat- themed projects, and may look out of place on a stock “cruiser” style bike.
d) Also, the fluid outlet port (where the brake hose attaches), is facing "inward", towards the centerline of the bike (when the forks are pointed straight forward). The HCP1808WO master cylinders have their fluid outlet port facing straight forward, and therefore your stock brake line has to be contorted to a rather odd angle to make it reach and fit this forward-facing outlet port. We do have available modified rubber or braided stainless steel brake lines for use of the aftermarket master cylinders on these bikes; their end fitting is rotated by the 90-degrees and extended by an appropriate length to allow it to attach to the aftermarket master cylinders properly.
e) If you want to retain the original low brake fluid warning feature, the only way to do this is to rebuild your original master cylinder, or, to obtain a correct used master cylinder (off of another 1982 XJ750 Maxim model) and rebuild it. Let us know if you are interested in this option and we can provide a full list of recommended rebuild parts.
Aftermarket Front Master Cylinders:
HCP3063WO Aftermarket complete MASTER CYLINDER ASSEMBLY, brand new aftermarket unit perfectly replaces your original. Comes with cover, diaphram, piston assembly, hand lever, mounting hardware, union bolt, and crush washer----completely ready to install. Fits all North American XJ550 models, although the hand lever that comes with this master cylinder will not have the same bend orientation as original. 13mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. NOTE: this aftermarket master cylinder can also be used in place of the original master cylinder on XJ650 Maxim and Midnight Maxim models, as well as all XJ1100 models, but because those are "level" orientation master cylinders, they will place the mirror mounting boss in a different position (and odd angle) compared to the original master cylinders on those models. Will also fit the following non-XJ bikes: 1982-83 all XS400 Maxim and Seca, 1982 XZ550 Vision, 1984-95 XT600, and 1987 SRX250 models. NOTE: brake light switch is not included with this master cylinder and the proper switch should be ordered separately if needed. NOTE: the HCP2667 clutch hand lever is the closest available match in style and finish to the hand lever that comes with this master cylinder. NOTE: this master cylinder has the proper left-hand threads for the stock Yamaha mirrors. This means that any other brand---Kawasaki, Honda, Suzuki, etc.---mirrors will not fit it, since all models besides Yamaha used standard right-hand threads for both the left and right side mirrors). Only Yamaha used left-hand threads on the right side mirror. If you wish to use your stock (or other) Yamaha mirrors with this master cylinder, you can use our mirror adaptors listed below.
$ 129.95
HCP1808WO Aftermarket complete MASTER CYLINDER ASSEMBLY, brand new aftermarket unit perfectly replaces your original. Comes with cover, diaphram, piston assembly, hand lever, mounting hardware, union bolt, and crush washer----completely ready to install. Fits all XJ550 non-North American models, XJ650 Maxim/Midnight Maxim models, 1982 XJ650RJ or RJC Seca models, all non-North American XJ650 models, all XJ700 and XJ750-X models, 1984 XJ750RL, all XJ900RK, RL, N/FN, and F models, and XJ1100 models. The hand lever that comes with this master cylinder will not have the proper bend orientation to match all models. NOTE: brake light switch is not included with this master cylinder and the proper switch should be ordered separately if needed. This cylinder does NOT have the provision for the low brake fluid sensor as used on the XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L) models. 16mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port. NOTE: the HCP2667 clutch hand lever is the closest available match in style and finish to the hand lever that comes with this master cylinder. See application notes below in regards to the use of this master cylinder on XJ650 Maxim/Midnight Maxim, 1983 XJ750 Maxim/Midnight Maxim models, and XJ1100 models. NOTE: this master cylinder has the proper left-hand threads for use with the stock Yamaha mirrors. This means that any other brand---Kawasaki, Honda, Suzuki, etc.---mirrors will not fit it, since all models besides Yamaha used standard right-hand threads for both the left and right side mirrors). Only Yamaha used left-hand threads on the right side mirror. If you wish to use your stock (or other) Yamaha mirrors with this master cylinder, you can use our mirror adaptors listed below.
$ 119.95
Application notes:
a) because the stock OEM master cylinders on XJ650 Maxim/Midnight Maxim, the 1983 XJ750 Maxim/Midnight Maxim models, and XJ1100 models is designed to be used on the stock curvy "buckhorn" style handlebars, the stock master cylinder reservoir is oriented at a "tilted" (from horizontal) mounting angle. This "tilting" allows the mirror to be properly aligned for the use with the stock buckhorn bars and keeps the reservoir in a relatively level position.
b) the aftermarket master cylinder HCP1808WO is designed to mounted on "flat" (or, at least, "flatter") style handlebars, such as the ones found originally on all XJ-series bikes (except the XJ650 Maxim/Midnight Maxim, XJ750 Maxim/Midnight Maxim, or the XJ1100 models.....all of these models used tilted or curvy “buckhorn” style bars). All other models use fairly flat handlebars, and thus the replacement HCP1808WO master cylinder will work on those bikes correctly; they leave the mirror mounted in the proper orientation.
c) thus the aftermarket HCP1808WO master cylinder is going to leave the stock mirror tilted at a rather crazy and semi-useless angle when installed on any model that had those curvy, "buckhorn" style bars, and we do not have a stock-style mirror substitute that "solves" this problem. About the only solution we offer is to use the "bar-end" style mirrors, which attach the mirrors to a mounting stem that fits inside the end of the handlebars (which requires modification of the grips by cutting away the rubber on the ends of them, but that is easy enough to do). Of course bar-end mirrors are kind of a unique looks, usually reserved for café- and bobber/rat- themed projects, and may look out of place on a stock “cruiser” style bike.
d) Also, on the XJ650 Maxim/Midnight Maxim models, the fluid outlet port (where the brake hose attaches), is facing "inward", towards the centerline of the bike (when the forks are pointed straight forward). The replacement HCP1808WO master cylinders have their fluid outlet port facing straight forward, and therefore your stock brake line has to be contorted to a rather odd angle to make it reach and fit this forward-facing outlet port. We do have available modified rubber or braided stainless steel brake lines for use of the aftermarket master cylinders on these bikes; their end fitting is rotated by the 90-degrees and extended by an appropriate length to allow it to attach to the aftermarket master cylinders properly.
e) If you want to retain the original low brake fluid warning feature, the only way to do this is to rebuild your original master cylinder, or, to obtain a correct used master cylinder (in regards to the 1982 XJ750 Maxim and XJ1100 models) and rebuild it.
Mirror Thread Adaptors:
Yamaha was unique in using left-hand (reverse) threads for the right side mirror........this allows the right-side mirror to "rotate loose" in case you hit something with it, rather than snapping the mirror stem (or master cylinder). Although this is a great and clever idea, it causes difficulties when using aftermarket or non-stock master cylinders, as they will not have the proper thread orientation needed to install the stock mirror. Our MIRROR ADAPTORS will allow you to use the stock Yamaha right side mirror on aftermarket master cylinders which have standard right-hand threads in the mirror mount bore.
HCP13236 Aftermarket set of MIRROR THREAD CONVERTERS, allows the use of any right-hand threaded, right side mirror on any stock Yamaha master cylinder that has the reverse left-hand threads for the mirror mounting. This adapter simply screws into the left-hand threaded hole in the master cylinder, and it has male right-hand threads in its upper receiver where a non-Yamaha mirror can mount into. These units will raise the height of the mirror by approximately 5/8" above the original mirror mounting point (on the master cylinder), Matched set does both the left and right side mirrors. These adaptors feature a low-gloss black finish.
$ 14.95
HCP13237 Aftermarket set of MIRROR THREAD CONVERTERS, allows the use of any right-hand threaded, right side mirror on any stock Yamaha master cylinder that has the reverse left-hand threads for the mirror mounting. This adapter simply screws into the left-hand threaded hole in the master cylinder, and it has male right-hand threads in its upper receiver where a non-Yamaha mirror can mount into. These units will raise the height of the mirror by approximately 5/8" above the original mirror mounting point (on the master cylinder), Matched set does both the left and right side mirrors. These adaptors feature a high-polish chrome finish.
$ 19.95
Brake Hand Lever Cover or Boot:
hl11) Original flexible rubber accordion brake hand lever BOOT protects the hinge mechanism and switch from excess moisture and dirt. Note that XJ700 and XJ750-X models do not use a hand lever boot, but if you want to equip either of those models with a boot, then use either the HCP608 or HCP16520 versions listed below. Note that due to the extra-large "ball" end of the hand lever on the XJ700 and XJ750-X models, you will need to generously lubricate (dish soap, silicone, etc.) the rubber boot opening so that it can slide over the knob without tearing/splitting.
The HCP3063WO and the HCP1808WO master cylinders above come with the brake hand lever, but do not come with the protective boot, which you may want to add:
HCP608 OEM black accordion-pleated BRAKE HAND LEVER BOOT, correct fit and appearance as original. Fit all XJ550 models, all XJ650 models, all XJ750 Maxim and Midnight Maxim models, XJ750P (24L and 37H models), XJ1100, and all XS1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders.
$ 21.95
HCP16520 Aftermarket black accordion-pleated BRAKE HAND LEVER BOOT, correct fit and appearance, more durable material than original. Fit all XJ550 models, all XJ650 models, all XJ750 Maxim and Midnight Maxim models, XJ750P (24L and 37H models), XJ1100, and all XS1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders.
$ 17.95
Front Master Cylinder Mounting Hardware:
HCP3027 OEM front master cylinder mounting BRACKET CLAMP. c-shaped, flat black clamp used to retain the front master cylinder and reservoir unit to the handlebars. Used on all the following models: all XJ550, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H model), XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders.
$ 28.95
HCP10145 OEM front master cylinder mounting BRACKET CLAMP. c-shaped, flat black clamp used to retain the front master cylinder and reservoir unit to the handlebars. Fits 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and all XJ900N, FN, and F models, as well as the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200. Features the 16mm piston bore, horizontally level reservoir orientation, forward-facing fluid outlet port.
$ 24.95
HCP24327 OEM front master cylinder mounting BRACKET CLAMP. c-shaped, flat black clamp used to retain the front master cylinder and reservoir unit to the handlebars. Used on all the following models: all 1992-98 XJ600 Seca II models.
$ 24.95
HCP3029 OEM front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard 6-point hex-head alloy steel bolt with a dark finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 3.95
HCP14007 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard 6-point hex-head alloy steel bolt with a yellow zinc-plated finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 1.95
HCP22249 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard 6-point hex-head 18/8 stainless steel bolt with a bright finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 2.95
HCP14008 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard 6-point hex-head 316 stainless steel bolt with a bright finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 3.95
HCP22253 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard socket head (allen-key drive) alloy steel with a yellow zinc-plated finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 1.95
HCP228 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard socket head (allen-key drive) alloy steel with a black-oxide finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 1.95
HCP2779 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard socket head (allen-key drive) alloy steel with a black-oxide finish, features self-locking threads. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 2.95
HCP226 Aftermarket front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Standard socket head (allen-key drive) 18/8 stainless steel with a bright finish. Use 2 per bracket. Fits all XJ550, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, XJ1100, and 1981 XS1100 Midnight Maxim models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 2.95
HCP971 OEM front master cylinder mounting bracket clamp BOLT, alloy steel, socket-head cap screw with a black finish, used to attach the bracket to the master cylinder. Fits all 1984-85 FJ600 and XJ900N models. Use 2 per bracket. Each.
$ 7.95
HCP2779 Aftermarket front master cylinder mounting bracket clamp BOLT, allen head hex-drive, natural finish, self-locking threads, used to attach the bracket to the master cylinder. Fits all 1984-85 FJ600 and XJ900N models. Use 2 per bracket. Each:
$ 2.95
HCP226 Aftermarket front master cylinder mounting bracket clamp BOLT, allen head hex-drive, black-oxide coated steel, used to attach the bracket to the master cylinder. Fits all 1984-85 FJ600 and XJ900N models. Use 2 per bracket. Each:
$ 2.95
HCP228 Aftermarket front master cylinder mounting bracket clamp BOLT, allen head hex-drive, black-oxide coated steel, used to attach the bracket to the master cylinder. Fits all 1984-85 FJ600 and XJ900N models. Use 2 per bracket. Each:
$ 1.95
HCP24328 OEM front master cylinder mounting bracket clamp BOLT, used to attach the bracket to the master cylinder. Fits all 1992-98 XJ600 Seca II models. Use 2 per bracket. Each.
$ 2.50
HCP1902 OEM front master cylinder mounting bracket clamp LOCK WASHER, black oxide-coated alloy steel, used with the above attaching bolts. Use 2 per bracket. Fits all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 6.95
HCP916 Aftermarket front master cylinder mounting bracket clamp LOCK WASHER, zinc-plated alloy steel with a bright finish, used with the above attaching bolts. Use 2 per bracket. Fits all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 1.95
HCP319 Aftermarket front master cylinder mounting bracket clamp LOCK WASHER,18-8 stainless steel, used with the above attaching bolts. Use 2 per bracket. Fits all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 2.95
HCP321 Aftermarket front master cylinder mounting bracket clamp LOCK WASHER, black oxide-coated alloy steel, used with the above attaching bolts. Use 2 per bracket. Fits all XJ550, 1984-85 FJ600, 1986-90 YX600 Radian, XJ650, XJ700, XJ750-X XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 1.95
HCP18010 Aftermarket master cylinder mounting bracket bolt hex head protective CAP. Black plastic pebble-grain finish cap snaps onto the hex head of the mounting bolts, giving them a very "modern" look, protecting the head from rust. Fits all XJ550, XJ650, XJ700, XJ750-X, XJ750 Maxim and Midnight Maxims, XJ750RL, XJ750P (24L model), XJ750P (37H) models, all XJ900RK, RL, and N/FN models, and XJ1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Each:
$ 3.50
HCP3933 OEM master cylinder-to-headlight bracket BOLT, 6-point hex head alloy steel fastener with a dark finish, use the HCP1902 lock washer listed below. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 3.95
HCP22180 Aftermarket master cylinder-to-headlight bracket BOLT, 6-point hex head alloy steel fastener with a dark finish, use the HCP1902 lock washer listed below. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 1.95
HCP22182 Aftermarket master cylinder-to-headlight bracket BOLT, 6-point hex head 18/8 stainless steel fastener with a bright finish, use the HCP1902 lock washer listed below. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 2.95
HCP22183 Aftermarket master cylinder-to-headlight bracket BOLT, 6-point hex head 316 stainless steel fastener with a bright finish, use the HCP1902 lock washer listed below. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 3.95
HCP22181 Aftermarket master cylinder-to-headlight bracket BOLT, 6-point hex head alloy steel fastener has a serrated flange (which eliminates the need for using a lockwasher) and features a dark finish. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 2.95
HCP1902 OEM master cylinder-to-headlight bracket LOCK WASHER, black oxide-coated alloy steel. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 6.95
HCP916 Aftermarket master cylinder-to-headlight bracket LOCK WASHER, zinc-plated alloy steel with a bright finish. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 1.95
HCP319 Aftermarket master cylinder-to-headlight bracket LOCK WASHER, 18-8 stainless steel. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 2.95
HCP321 Aftermarket black oxide-coated alloy steel master cylinder-to-headlight bracket LOCK WASHER. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 1.95
HCP318 Aftermarket master cylinder-to-headlight bracket MOUNTING SCREW, 18-8 stainless steel with an allen head and hex-drive. Use the HCP319 lock washer listed below. Use 1 for the upper mounting position on the front master cylinder on all XJ750 Seca and XJ750 Euro models.
$ 2.95
HCP319 Aftermarket master cylinder-to-headlight bracket mounting screw LOCK WASHER, 18-8 stainless steel. Use with the HCP318 screw listed above. Each.
$ 2.95
HCP3928 OEM master cylinder-to-headlight stay bracket mounting BOLT, alloy steel hex-head bolt with a black finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models.
$ 7.95
HCP17143 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, steel hex-head bolt with a bright silver-zinc finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 1.95
HCP22195 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, alloy steel hex-head bolt with a bright yellow-zinc finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 1.95
HCP17144 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, alloy steel hex-head bolt with a black finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 1.95
HCP17145 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, 18-8 stainless steel hex-head bolt with a bright finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 2.95
HCP22198 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, 316 stainless steel hex-head bolt with a bright finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 3.95
HCP22200 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, high-strength alloy steel socket head (hex-key) bolt with a black finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 3.95
HCP22201 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, alloy steel socket head (hex-key) bolt with a bright finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 1.95
HCP22202 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, 18-8 stainless steel socket head (hex-key) bolt with a bright finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 2.95
HCP24125 Aftermarket master cylinder-to-headlight stay bracket mounting BOLT, 316 stainless steel socket head (hex-key) bolt with a bright finish, used to attach the master cylinder to the headlight bracket. For the lower mounting position on the master cylinder. Use 1 per bike. Fits all XJ750 Seca and XJ750 Euro models:
$ 3.95
HCP2391 OEM master cylinder-to-headlight stay bracket mounting bolt LOCK WASHER, use 1 per bike on all XJ750 Seca and XJ750 Euro models.
$ 7.95
HCP16209 Aftermarket master cylinder-to-headlight stay bracket mounting bolt LOCK WASHER, zinc-plated alloy steel, use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 2.95
HCP16100 Aftermarket master cylinder-to-headlight stay bracket mounting bolt LOCK WASHER, 18-8 stainless-steel with a bright finish, use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 3.95
HCP16102 Aftermarket master cylinder-to-headlight stay bracket mounting bolt LOCK WASHER, black-oxide coated alloy steel, use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 3.95
HCP3945 OEM master cylinder-to-headlight stay bracket mounting bolt FLAT WASHER, alloy steel, black finish. Use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 4.95
HCP26192 Aftermarket master cylinder-to-headlight stay bracket mounting bolt FLAT WASHER, alloy steel, bright finish. Use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 1.95
HCP26193 Aftermarket master cylinder-to-headlight stay bracket mounting bolt FLAT WASHER, 18/8 stainless steel, bright finish. Use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 2.95
HCP17110 Aftermarket master cylinder-to-headlight stay bracket mounting bolt FLAT WASHER, 316 stainless steel, dull finish. Use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 3.95
HCP26189 Aftermarket master cylinder-to-headlight stay bracket mounting bolt FLAT WASHER, alloy steel, black finish. Use 1 per bike on all XJ750 Seca and XJ750 Euro models. Each:
$ 2.95
FRONT MASTER CYLINDER REBUILD PARTS:
mc41) OEM and aftermarket brake MASTER CYLINDER REBUILD KITS contain all the operational parts you need to correctly rebuild your master cylinder: piston, piston seal, piston spring, piston rubber sealing boot, and retaining circlip. NOTE: the piston seal does not come pre-installed onto the piston, and at first glance, you may wonder "how the heck do you get that small seal opening over that large piston?". Well, lots of lube (brake fluid) and patience and a small, dull pry tool works wonders. Make sure that you install the seal with the flared seal "lip" facing towards the fluid outlet!
Yamaha actually specifies that your master cylinder should be rebuilt every 2 years.
Master cylinder rebuild kits contain the piston, the piston seal, the spring, the plunger end seal, the plunger dust boot and its retaining circlip.
A pictorial overview of the master cylinder rebuild process can be observed at:
http://xjbikes.com/forums/index.php?threads/18377
and
http://www.venturerider.org/forum/showthread.php?116337-Clutch-Hydraulic-Rebuild-Tutorial
and
https://www.xjbikes.com/forums/threads/1985-86-xj700-caliper-rebuild.118121/page-2
and a couple of good videos:
www.youtube.com/watch?v=njKRhPwHOaM
and
www.youtube.com/watch?v=0BrHublevTE
and
NOTE1: be sure you very carefully clean and inspect your used, original master cylinder for any damage and verify that it can be rebuilt. If the pressed-in steel piston bore is badly scarred or pitted-rusted, then it must be honed to a silky-smooth finish before installing new components. If pits or scratches are too deep to be removed, it is best to obtain a replacement master cylinder (new or used) rather than to try to rebuild a damaged original. Remember, your life literally depends on your brakes....not always in day-to-day riding, but when it counts the most, in an emergency situation; and those always happen in the blink of an eye, and without prior warning.....
NOTE2: All original Yamaha front master cylinders have an extremely tiny "blow back" hole (actually a pressure release return passage) in the center of the bottom of the reservoir floor that must be clear and un-blocked in order for your master cylinder to function properly----if this hole is plugged, it will prevent the calipers from fully releasing when the brakes are NOT being applied, causing the brakes to always be slightly engaged. Brake system "dragging" will result, as well as brake rotor over-heating and warpage after a period of time.
This tiny hole is located within an area that is best described as what appears to be the beginning of a drilled hole that was "never completely drilled through" (this will make sense when you actually view the floor of the reservoir). In the very center of such area is this pressure release passage, and it takes about 1-2 un-stranded strands of wire to poke through this hole and remove any debris or gunk. This hole is not the much larger reservoir-to-piston chamber fluid transfer hole, which is huge compared to this pressure-relief passage. The pressure relief passage hole is normally just to the "side" or "behind" the larger (1mm diameter) fluid transfer hole, and "in line" with the centerline of the piston chamber, but "behind" the fluid transfer hole, towards the brake fluid output port.
When rebuilding your master cylinder, make sure that this tiny relief passage is free and clear! Failure to clean this passage fully is one of the major over-looked "gotch-ya!" situations that arise when rebuilding your master cylinder.
A good picture of this relief port on the conventional (handlebar-mounted) master cylinders can be seen at:
http://xjbikes.com/forums/index.php?threads/12529
while XJ750 Seca owners will have to look here:
http://xjbikes.com/forums/index.php?threads/14836
You will need an incredibly fine wire or drill bit to purge this relief hole from hardened gunk:
HCP12929 Aftermarket master cylinder pressure-relief port CLEAN OUT WIRE PROBE TOOL, hand-held port probe tool has the proper size wire needed to punch this hole clean, allowing you to either push through or twist the wire to act as a "drill bit". For all XJ-series master cylinders.
$ 12.95
HCP11177-12" Aftermarket master cylinder pressure-relief port CLEAN OUT WIRE, 1-foot length of the proper size wire (wire only, no holder included) needed to punch this hole clean. For all XJ-series master cylinders.
$ 4.95
HCP2296 Aftermarket master cylinder pressure-relief port CLEAN OUT DRILL BIT, hand-held port probe drill bit is the proper size to punch this hole clean, allowing you to either push through or twist the bit by hand (it is too small to fit into a standard drill chuck, so it must be used by hand or in a pin-vise). For all XJ-series master cylinders.
$ 12.95
NOTE3: this tiny hole is also why it is so hard to bleed motorcycle brakes on a “dry” (freshly rebuilt) system; here’s the images and write-up that explains it all, and is a great way to understand how your master cylinder actually operates:
https://www.xjbikes.com/forums/thre...o-your-yamaha-today.4769/page-416#post-682247
You will also find your life being made a lot easier with the use of these special deep-reach circlip pliers, need to extract (and install) the internal circlip that holds the entire guts in the master cylinder:
bp1) Master Cylinder DEEP-REACH CIRCLIP PLIERS----these special extra-deep 90-degree angled circlip pliers allow you to easily remove and install the circlip (or "c'-clip) that hides way down inside the top of the plunger bore (below the rubber boot). Without a DEEP set of circlip pliers, you're going to fight and struggle with this part of your master cylinder rebuild project. Regular store-bought circlip pliers may have a 90-degree attachment, but unless they are extra-deep like these, they still won't be able to reach that circlip.
HCP1597 Aftermarket master cylinder CIRCLIP PLIERS, each:
$ 37.95
These and other special tools can be found in the BRAKE TOOLS SECTION of the catalog at the very end of this brake parts section.
You can check the condition of your master cylinder by disconnecting the brake hose at the master cylinder and performing a bench test by plugging off the fluid exit port and operating the hand lever to see if it will build pressure. If it does, then the master cylinder seals are in good condition. If, however, the master cylinder spurts fluid back up through the pressure-relief port, then a rebuild is definitely in order! NOTE: it is proper and correct for brake fluid to squirt up through this pressure relief hole only when the piston is retracting (hand lever released), as this is how the master cylinder relieves excess pressure from the brake calipers so the pads back off the rotors. But if the relief passage is plugged, your brakes will drag.
Of course, once you rebuild the master cylinder, you should perform the bench-test procedure once again, to make sure you have rebuilt it correctly. In either situation, you should bleed your brakes (and perhaps flush all of the old fluid) whenever the brake system has been opened, as well as replacing the crush washers at the master cylinder union bolt.
NOTE: if your master cylinder fails to build pressure after a rebuild, you may have installed the rubber piston seals or the plunger spring incorrectly (backwards).
Frequently, the question comes up as to how the various component bits and pieces of the replacement master cylinder kits should be installed.....as the fluid plunger (piston) can be installed in two different orientations within the bore, and the rubber fluid seals can also be oriented in two different directions. In order for your master cylinder to operate properly, it is vital that you get all of these orientations correct!
Also, please be aware that the factory diagrams and illustrations in both the factory service manuals and in the aftermarket service manuals illustrate the original factory piston and components, and thus tend to appear to be "wrong" in comparison to the contents of the currently available rebuild components.....actually, the illustrations are correct, but aftermarket master cylinder rebuild kits do away with the separate rubber spring "cup seal" that is illustrated in the original factory diagrams. Instead, the aftermarket kits place the forward fluid pressure seal onto the piston itself (rather than resting at the end of piston), and this combined "forward pressure seal and spring cup" is thus eliminated in the replacement rebuild kits-----the spring fits over the end "snout" of the piston unit, rather than into the original rubber "cup" seal.
The factory drawings can lead one to believe that the plunger/piston is originally of a 2-piece design; this is not correct, they are always a 1-piece design and the original separate forward pressure seal/spring "cup" makes the drawings appear as if the not fully or correctly illustrated piston is actually two pieces!
Here's how it really works: by the way, it is very helpful if you carefully note or mark the original piston as it is extracted out of the master cylinder bore, in order to eliminate confusion later.
The replacement piston has three seal location "lands" where a seal fits ("lands") onto the piston. Two of these lands are for the fluid pressure seals....one on each end of the three spiraling "corkscrew" fluid reliefs....while the one land near the "fat" end of the piston is where the large rubber weather-tight boot is placed.
Please note carefully that the two fluid pressure seals have different size internal diameter openings, and thus fit onto their corresponding smaller and larger diameter seal lands at each end of the "corkscrew". These seals fit with their open face or "lips" facing towards the fluid output port of the master cylinder.
The tapered return spring has different sized ends; the smaller end fits over the small "stud" or "snout" of the piston. The larger end of the spring will thus be the first object that "enters" the master cylinder bore as you re-assemble the piston into the master cylinder bore.
Please note right here that the drawings in the factory service manual do not illustrate this small "snout" on the piston end (where the small end of the return springs fits over), and thus the entire diagram can lead you to believe that this small "snout" actually fits toward the hand lever, which is incorrect!
If you ever get confused as to which end of the piston is which, look at your original piston, and note which end face has scars and (probably) metal displacement from it very end face..........the one that shows the metal displacement is the one that the hand lever was operating upon!
The large rubber "boot" fits into the ring land that is near the lever-end of the piston, and it fits "down" towards the length of the piston, not "outwards". You will note that the large open end of this boot actually has a stiff metal ring embedded within it.
This rubber boot will be the last thing that is installed, after the piston unit has been installed into the master cylinder bore, the piston depressed, and the retaining circlip installed. Only then can the rubber boot be installed onto the end of the piston.
Assembly Notes:
- make sure that the internal master cylinder bore is completely clean, smooth, and free of nicks, junk, gunk, and old fluid or rubber remnants.
- lubricate the master cylinder bore and the entire piston assembly with clean brake fluid before trying to install the piston into the master cylinder bore.
- make sure that the seal lips do not "turn inside out" or "roll back" on themselves as the plunger is inserted into the m/c............a "rotating" motion of the plunger as it is being inserted can be useful in preventing such as occurrence.
- the wide end of the spring goes toward the fluid outlet port.
- the piston rubber pressure rings that goes around the plunger have an open face with a lip on it....and that lip should be oriented "in" towards the fluid outlet port.
- the metal circlip that retains the plunger in the cylinder bore goes on before the outer plunger dust boot is installed.
If you are re-using the original master cylinder components, then:
- the open end of the hat-shaped rubber cup goes over the narrow end of the spring.........and that lip should be oriented "in" towards the fluid outlet port.
Here is a good image of a correctly set-up piston, with all of the seal and spring orientation done properly:
http://xjbikes.com/forums/index.php?threads/48360
HCP12991 Aftermarket master cylinder fluid output port BLOCK-OFF PLUG, correct size allen-head set-screw is used to replace a brake hose union bolt while pressure testing the master cylinder. Fits all XJ-series front or rear master cylinders except XJ750 Seca front and XJ1100 rear master cylinders.
$ 6.95
HCP15676 Aftermarket master cylinder fluid output port BLOCK-OFF PLUG, correct size allen-head set-screw is used to replace a brake hose union bolt while pressure testing the master cylinder. Fits all XJ750 Seca front, XJ1100 rear master cylinders, and XJ1100 rear proportioning valve fluid inlet port from the rear master cylinder.
$ 3.95
Front Master Cylinder Rebuild Kits:
These OEM and aftermarket kits contain the correct parts needed to rebuild your original master cylinder. Most kits are available in either a basic of full version as described below:
SEALS AND SPRING KITS contain the piston seals, return spring, piston boot, piston retainer clip, and a pair of union bolt crush washers. Since these kits contain all of the main “wear parts”, it’s now affordable to actually follow Yamaha’s suggested rebuild interval (every 2 years) without “braking” (pun intended!) the bank! Other parts needed to properly rebuild an original master cylinder --- the piston, the fluid level sight window, cover, cover diaphragm, cover screws or nuts, mounting clamps, fluid level sensor hardware (when used), etc. are not included.
BASIC REBUILD KITS contain the typical main working “guts” of your master cylinder: the aluminum piston, its seals, return spring, spring cup (when used), piston boot, and its retainer clip. Other parts needed to properly rebuild an original master cylinder --- the fluid level sight window, cover, cover diaphragm, cover screws or nuts, mounting clamps, fluid level sensor hardware (when used), etc. are not included.
FULL REBUILD KITS contain all of the items in the basic rebuild kit, plus a fluid return hole clean-out wire, the replacement fluid level glass sight window (on models which use them), adhesive for the glass window, a packet of assembly grease, the reservoir cover diaphragm, the cover screws, and ---- models requiring them ---- the fluid level sensor hardware and sealing o-ring.
Don’t forget that these rebuild tools can make the rebuild process easier and more complete:
HCP1597 Aftermarket master cylinder DEEP-REACH CIRCLIP PLIERS, these special extra-deep 90-degree angled circlip pliers allow you to easily remove and install the circlip (or "c'-clip) that hides way down inside the top of the plunger bore (below the rubber boot). Without a DEEP set of circlip pliers, you're going to fight and struggle with this part of your master cylinder rebuild project. Regular store-bought circlip pliers may have a 90-degree attachment, but unless they are extra-deep like these, they still won't be able to reach that circlip. Each:
$ 37.95
HCP2396 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For use on all XJ-series (except XJ750 Seca and XJ750 Euro models with cable-operated master cylinder) and 1981 XS1100 Midnight Special front master cylinder cover hold-down screws.
$ 9.95
HCP2397 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For use on all XS1100 front master cylinder cover hold-down screws (except 1981 XS1100 Midnight Special models).
$ 9.95
HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95
Aftermarket master cylinder PISTON BORE FLEX-HONE. If you want to rebuild your master cylinder correctly, like a professional would, then you'll need the correct tools-----and this is one of them.
These flexible ball-tipped wire cylinder hones are especially made to give the master cylinder piston bore a gentle and proper hone pattern, removing minor surface imperfections and buildup that simply cannot be reached in any other way. Design allows full reach to end of piston bore for complete precision coverage. Super-fine 320-grit material provides the necessary toughness to properly refinish the bore. NOTE: the stranded wire "shaft" of these hones will fit into most drill chucks, but it is advised you perform the operation at a very slow speed, and for no more than 30-45 seconds. ALWAYS KEEP THE HONE MOVING WITHIN THE BORE IF OPERATING WITH A DRILL, AND KEEP THE STONES FULLY LUBRICATED WHEN IN USE!
HCP1743 Aftermarket master cylinder piston bore FLEX HONE, for use with all XJ550 North American (single disc brake) master cylinders, 1984-85 FJ600 rear master cylinder, 1992-98 XJ600 Seca II front or rear master cylinders, all XJ650 Maxim and Midnight Maxim master cylinders, XJ900 models rear master cylinder, and XJ1100 front master cylinder. Each:
$ 59.95
HCP1744 Aftermarket master cylinder piston bore FLEX HONE, for use with all XJ550 European (dual disc brake) master cylinders, 1984-85 FJ600 front master cylinder, XJ650RJ Seca and XJ650 Turbo master cylinders, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxim models, 1984 XJ750RL front and all XJ900 front master cylinders. Each:
$ 59.95
HCP1745 Aftermarket master cylinder piston bore FLEX HONE, for use on all XJ750 Seca, XJ750 Euro, all XS1100 (except 1981 XS1100LH Midnight Special) front master cylinders, and the 1981 XS1100LH Midnight Special rear master cylinder. Each:
$ 59.95
HCP1746 Aftermarket master cylinder piston bore FLEX HONE, for use on all XJ1100 rear master cylinders. Each:
$ 59.95
HCP22816 Aftermarket valve guide hone HONING OIL, this is the proper lubricant to use with any of the above cylinder hones. 1/2 pint bottle is enough to do many, many master cylinders.
$ 21.95
NOTE: before ordering your master cylinder rebuild parts, please take a moment to inspect and confirm that your bike does indeed have a factory original (for your model) master cylinder on it. After all these years….and so many previous owners…...there’s no telling what’s resting up there on your handlebars, and since rebuild parts are quite specific designed to work only with a particular style master cylinder ----- well, it’s best to be safe than sorry!
So here are the clues for original master cylinder identification:
XJ550 all North American models: the cylinder body will have the size 1/2 and the word NISSIN cast into it along the larger rear facing side of the cylinder body. Original (1981-83) cylinders will have the word NISSIN in all capital, block-style letters, while later “replacement” cylinders will have the word NISSIN appear as a stylized semi-script, with the two “s” letters layered on top of each other. Both types will accept all of the parts that we have listed below as fitting original master cylinders. Note that 1/2” = 13.7mm.
XJ550 non-North American models (dual-disc bikes): the cylinder body will have the word NISSIN cast into it along the larger rear facing side of the cylinder body, and have the size 5/8 cast into the forward face of the cylinder body just to the left of the fluid outlet port (where the brake line attaches). Note that 5/8” = 16mm.
1984-85 FJ600 and all XJ900 F, N, and FN models: the cylinder body will have the size 5/8 (meaning a 5/8" = 16mm bore) cast into large front face side of the cylinder body just above the fluid outlet port (where the brake line attaches), and the manufacturer name does not appear anywhere on the cylinder body.
XJ600 Seca II models: the cylinder body will have the size 14 (meaning a 14mm bore) cast into large front face side of the cylinder body, and the manufacturer name does not appear anywhere on the cylinder body.
XJ650 Maxim and Midnight Maxim North American models (single-disc): the cylinder body will have the size 14 (meaning a 14mm bore) and the word NISSIN cast into it along the rear face of the piston bore. Also note that these cylinder bodies have a "tilted orientation" to compensate for their "angled" handlebars.
XJ650 non-North American (dual disc) models, XJ650RJ Seca, all XJ700, XJ750-X, XJ750RL, and XJ900RK and RL models: the cylinder body will have the word NISSIN cast into it along the larger rear facing side of the cylinder body, and have the size 5/8 (meaning a 5/8" = 16mm bore) cast into the forward face of the cylinder body just to the left of the fluid outlet port (where the brake line attaches).
XJ650 Turbo, 1982-83 XJ750 Maxim and Midnight Maxim, and all XJ750 Police models: the master cylinder body will have the size 5/8 (meaning a 5/8" = 16mm bore) cast into it along the larger rear facing side of the cylinder body, and the word NISSIN does not appear anywhere on the cylinder body. The XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P master cylinders have a small (1/4” diameter) hole in the base of the reservoir where the fluid level sensor wires exit the inside of the reservoir. Also note that both the 1982 and 1983 XJ750 Maxim/Midnight Maxim model cylinder bodies have a "tilted orientation" to compensate for their "angled" handlebars.
XJ750 Seca and all XJ750 Euro models: the long skinny cylinder body will have the size 11/16 (meaning a 17.5mm bore) cast into it along on side the piston bore, and the word NISSIN does not appear anywhere on the cylinder body. A good image of this type cylinder can be seen at: http://www.xjbikes.com/forums/threads/new-member-need-help-with-brakes.78654/#post-492845
XJ1100 Maxim and Midnight Maxim models: the cylinder body will have the size 14 (meaning a 14mm bore) cast into it along the rear face of the piston bore, and the word NISSIN does not appear anywhere on the cylinder body. The bottom of the reservoir has a small (1/4” diameter) hole in where the fluid level sensor wires exit the inside of the reservoir. Also note that these cylinder bodies have a "tilted orientation" to compensate for their "angled" handlebars.
NOTE: XJ750 Police (24L, 33V, and 39Y models) used the XJ650 Turbo master cylinder with XJ750 Seca calipers and rotors, and XJ650 Turbo style forks without anti-dive.
NOTE: XJ750 Police (37H models) used the XJ650 Turbo master cylinder with XJ650 Turbo/XJ750 Maxim/Midnight Maxim calipers, XJ650 Turbo rotors, and XJ900 style forks with anti-dive.
If your master cylinder does not match the above descriptions, then we may not be able to assist you with rebuild parts for it…..there are an incredible number of both original and aftermarket master cylinders that were/are available, they all look somewhat the same, and they all may or may not accept nor function properly (or at all!) with component intended for use with the original master cylinder used on your bike!
NOTE: many times you may end up needing the flexible rubber PLUNGER BOOT that sits on the end (outside of the piston bore), a it is very easy to rip this boot during installation or service (this is the boot that is held in place by the external circlip listed below). This boot is included in all of the following master cylinder rebuild kits, but it is also available separate if just that boot is needed:
HCP21232 Aftermarket master cylinder plunger rubber OUTER BOOT, fits all XJ-series (except 1992-98 XJ600 Seca II models) front master cylinders.
$ 11.95
NOTE: at times you may also end up needing just the CIRCLIP that retains the piston in its bore (the HCP21232 boot above fits over/on top of this circlip). This circlip is included in all of the following master cylinder rebuild kits, but it is also available separate if only it is needed:
HCP23015 Aftermarket master cylinder plunger rubber outer boot retaining CIRCLIP, black spring steel as original, fits all XJ-series (except 1992-98 XJ600 Seca II models) front master cylinders.
$ 3.95
HCP23016 Aftermarket master cylinder plunger rubber outer boot retaining CIRCLIP, 400-series stainless steel, fits all XJ- series (except 1992-98 XJ600 Seca II models) front master cylinders.
$ 4.95
HCP24780 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3030 OEM front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 119.95
HCP1694 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 69.95
HCP23630 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all North American XJ550 models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP9819 fluid level glass window for use on original master cylinders that used the Type B “clip-retained” plastic sight window. Comes with two sets of cover screws to accommodate models which used either the short or long cover screws (which varies by year). NOTE: most original master cylinders used the Type B window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 109.95
HCP23631 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all North American XJ550 models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP1074 fluid level glass window for use on original master cylinders that used the Type A “pressed-in” plastic sight window. Comes with two sets of cover screws to accommodate models which used either the short or long cover screws (which varies by year). NOTE: most original master cylinders did not used the Type A window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 109.95
HCP24782 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all 1984-85 FJ600, 1986-90 YX600 Radian, 1986-88 FZ600, and all XJ900N, FN, and F models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring. NOTE: the spring head “cap” and shim washer are not included and must be saved off of your original parts. Also fits all of the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
$ 29.95
HCP10142 OEM front MASTER CYLINDER BASIC REBUILD KIT for all 1984-85 FJ600, 1986-90 YX600 Radian, 1986-88 FZ600, and all XJ900N, FN, and F models. Contains the piston, both fluid seals, the return spring, the spring head cap, the shim washer, the plunger boot and its retainer ring. Also fits all of the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
$ 74.95
HCP23632 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all 1984-85 FJ600, 1986-90 YX600 Radian, 1986-88 FZ600, and all XJ900N, FN, and F models. Contains the piston, both fluid seals, the return spring, the spring head cap, the shim washer, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. Also fits all of the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
$ 109.95
HCP24783 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all 1992-98 XJ600 Seca II models. Contains both fluid seals, the return spring, and the retainer ring. .
$ 37.95
HCP19389 OEM front MASTER CYLINDER BASIC REBUILD KIT for all 1992-98 XJ600 Seca II models. Contains the piston, both fluid seals, the return spring, the spring head cap, the shim washer, the pushrod washer, the retainer ring, and a bottle of assembly oil.
$ 64.95
HCP23633 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all 1992-98 XJ600 Seca II models. Contains the piston, both fluid seals, the return spring, the spring head cap, the shim washer, the pushrod washer, the retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, a wire probe tool to clear out the pressure-relief port, and a bottle of assembly oil.
$ 99.95
HCP24329 OEM front master cylinder THREADED PLUNGER ROD, controls the adjustment of the brake hand lever. Fits all 1992-98 XJ600 Seca II front master cylinders.
$ 44.95
HCP2176 OEM front master cylinder NUT, use 1 on the threaded pushrod. Fits all 1992-98 XJ600 Seca II models. Each:
$ 4.95
HCP29085 Aftermarket front master cylinder NUT, use 1 on the threaded pushrod. Zinc-plated alloy steel. Fits all 1992-98 XJ600 Seca II models. Each:
$ 1.95
HCP24035 Aftermarket front master cylinder NUT, use 1 on the threaded pushrod. Made from 18-8 stainless steel. Fits all 1992-98 XJ600 Seca II models. Each:
$ 2.95
HCP24035 Aftermarket front master cylinder NUT, use 1 on the threaded pushrod. Fits all 1992-98 XJ600 Seca II models. Each:
$ 1.95
HCP24333 OEM front master cylinder threaded plunger rod CIRCLIP, fits all 1992-98 XJ600 Seca II front master cylinders.
$ 3.95
HCP3212 OEM brake hand lever pivot pin CIRCLIP, fits all 1992-98 XJ600 Seca II models. Each:
$ 7.95
HCP24334 OEM front master cylinder plunger rubber OUTER BOOT, fits all 1992-98 XJ600 Seca II front master cylinders.
$ 10.95
HCP24331 OEM front master cylinder HARDWARE KIT, contains a variety of small hardware pieces for mounting the hand lever to the master cylinder, including the return springs, handle pivot pin, circlip, washer, the knurled adjuster knob, special square washer, the HCP24333 circlip, and the HCP24334 rubber boot. Note that these are not parts that fit within the master cylinder body. For all 1992-98 XJ600 Seca II front master cylinders.
$ 109.95
HCP24781 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 K Virago models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3031 OEM front MASTER CYLINDER BASIC REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 K Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tube of red rubber brake grease.
$ 84.95
HCP1695 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 K Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tube of red rubber brake grease.
$ 57.95
HCP23634 Aftermarket front MASTER CYLINDER FULL REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinders, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-88, 1990, 1993, and 1995-00 XV535 Virago models, 1981-83 XV750 H/J/K Viragos, 1983 XV750MK Midnight Virago, and 1983 XV920 K/MK Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP9819 fluid level glass window for use on original master cylinders that used the Type B “clip-retained” plastic sight window. NOTE: most original master cylinders used the Type B window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 99.95
HCP23635 Aftermarket front MASTER CYLINDER FULL REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinders, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-88, 1990, 1993, and 1995-00 XV535 Virago models, 1981-83 XV750 H/J/K Viragos, 1983 XV750MK Midnight Virago, and 1983 XV920 K/MK Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP1074 fluid level glass window for use on original master cylinders that used the Type A “pressed-in” plastic sight window. NOTE: most original master cylinders did not used the Type A window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 99.95
HCP23636 Aftermarket front MASTER CYLINDER FULL REBUILD KIT, for all XJ1100 front master cylinders. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, the fluid level sensor o-ring, retaining clip, retaining screw and its washers, a packet of assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP9819 fluid level glass window for use on original master cylinders that used the Type B “clip-retained” plastic sight window. NOTE: most original master cylinders used the Type B window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 109.95
HCP23637 Aftermarket front MASTER CYLINDER FULL REBUILD KIT, for all XJ1100 front master cylinders. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, the fluid level sensor o-ring, retaining clip, retaining screw and its washers, a packet of assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP1074 fluid level glass window for use on original master cylinders that used the Type A “pressed-in” plastic sight window. NOTE: most original master cylinders did not used the Type A window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 109.95
HCP24779 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL Seca, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3032 OEM front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920 J Virago, 1981-82 XV920 RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 84.95
HCP1696 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 59.95
HCP23638 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all non-North American XJ650 models with dual front disc brakes, all XJ700 and XJ750-X models, 1983 XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP1074 fluid level glass window for use on original master cylinders that used the Type A “pressed-in” plastic sight window. NOTE: comes with two sets of cover screws to accommodate models which used either the short or long cover screws (which varies by year and model). NOTE: most original master cylinders used the Type A window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 119.95
HCP24118 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all non-North American XJ650 models with dual front disc brakes, all XJ700 and XJ750-X models, 1983 XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP9819 fluid level glass window for use on original master cylinders that used the Type B “clip-retained” plastic sight window. NOTE: comes with two sets of cover screws to accommodate models which used either the short or long cover screws (which varies by year and model). NOTE: most original master cylinders used the Type A window, but always verify before ordering: http://www.xj4ever.com/choosing a sight glass.pdf
$ 119.95
HCP23639 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all XJ650 Turbo models, XJ750P Police (all models), and 1982 XJ750 Maxim models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, the fluid level sight glass, a tube of gasket maker material for sight glass installation, reservoir diaphragm, reservoir cover screws, the fluid level sensor o-ring, retaining clip, retaining screw and its washers, a packet of assembly grease, and a wire probe tool to clear out the pressure-relief port. This kit includes the HCP1074 fluid level glass window for use on original master cylinders that used the Type A “pressed-in” plastic sight window. NOTE: comes with two sets of cover screws to accommodate models which used either the short or long cover screws (which varies by year and model).
$ 119.95
HCP3033 OEM MASTER CYLINDER BASIC REBUILD KIT for all XJ750 Seca and XJ750 Euro models. Contains the piston, piston seal, spring, spring cup seal, plunger rubber boot, and retaining snap ring. Does not include the HCP11150 bushing or the HCP11149 reservoir fills screw below.
$ 279.95
HCP23098 Aftermarket MASTER CYLINDER BASIC REBUILD KIT for all XJ750 Seca and XJ750 Euro models. Contains the piston seal, spring cup seal, plunger rubber boot, retaining snap ring, reservoir bushing, fluid level sensor c-clip, fluid level shaft o-ring, fluid shaft e-clip, reservoir fill-screw o-ring, and a packet of brake grease. Note that you will need to re-use your original piston and spring, which are not included in this kit.
$ 119.95
HCP23155 Aftermarket MASTER CYLINDER FULL REBUILD KIT for all XJ750 Seca and XJ750 Euro models. Contains the piston, piston seal, spring cup seal, plunger rubber boot, retaining snap ring, reservoir bushing, fluid level sensor c-clip, fluid level shaft o-ring, fluid shaft e-clip, reservoir fill-screw o-ring, and a packet of brake grease. Note that you will need to re-use your original spring, which is not included in this kit.
$ 149.95
HCP11150 Aftermarket front master cylinder-to-fluid reservoir rubber BUSHING, fits in-between the master cylinder and the fluid reservoir. A commonly deteriorated parts that should be replaced when rebuilding the master cylinder. Fits all XJ750 Seca and XJ750 Euro models.
$ 19.95
HCP11149 Aftermarket fluid reservoir FILLER SCREW, plastic hex-drive screw with o-ring. Fits all XJ750 Seca and XJ750 Euro models.
$ 17.95
We also have available replacement hardware for the fulcrum arm pivot bolt used on these models, but you will need to use a special thin mounting nut in place of the original nylon-insert locking nut, and we also recommend the use of a thread-locking fluid on the pivot bolt threads:
HCP16571 Aftermarket brake fulcrum arm mounting PIVOT BOLT SET, includes the pivot bolt, the lock washer, and the retaining nut. For all XJ750 Seca and XJ750 Euro models. Bright polished finish.
$ 9.95
HCP14428 OEM front MASTER CYLINDER BASIC REBUILD KIT, for 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, piston seal, spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease.
$ 119.95
HCP14429 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, piston seal, spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease.
$ 59.95
HCP23640 Aftermarket front MASTER CYLINDER FULL REBUILD KIT, for 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, the reservoir cover and screws, reservoir diaphragm and bushing, a wire probe tool to clear out the pressure-relief port, and a packet of assembly grease.
$ 169.95
HCP10584 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for the aftermarket HCP3063WO master cylinder only. DOES NOT FIT ANY ORIGINAL MASTER CYLINDER!!
$ 49.95
HCP9112 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for the aftermarket HCP1808WO master cylinder only. DOES NOT FIT ANY ORIGINAL MASTER CYLINDER!!
$ 49.95
for XS (except XS1100) models:
HCP24780 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3030 OEM front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 119.95
HCP1694 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 69.95
HCP14428 OEM front MASTER CYLINDER BASIC REBUILD KIT, for all 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, piston seal, spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease.
$ 119.95
HCP14429 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for all 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, piston seal, spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease.
$ 59.95
HCP23640 Aftermarket front MASTER CYLINDER FULL REBUILD KIT for all 1977-83 all XS650 models, 1977-79 all XS750 models, 1980-81 all XS850 models, 1978 XS500, 1978-81 XS1100 Standards, 1979-81 XS1100 Specials (except Midnight Special), and 1980 XS1100 Midnight Special front master cylinders. Contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, the reservoir cover and screws, reservoir diaphragm and bushing, a wire probe tool to clear out the pressure-relief port, and a packet of assembly grease.
$ 169.95
HCP29429 OEM front MASTER CYLINDER BASIC REBUILD KIT, for all 1976-77 XS360, 1977-79 XS400, 1980-81 XS400 Specials, 1978-81 SR500, 1976-78 XS500, 1977-79 XS650 Standards, 1978-80 XS650 Special, 1980-81 XS650 Special II, 1981-83 XS650 Heritage and Heritage Special models. Each kit contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease
$ 139.95
HCP26688 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for all 1976-77 XS360, 1977-79 XS400, 1980-81 XS400 Specials, 1978-81 SR500, 1976-78 XS500, 1977-79 XS650 Standards, 1978-80 XS650 Special, 1980-81 XS650 Special II, 1981-83 XS650 Heritage and Heritage Special models. Each kit contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease
$ 39.95
for XV, XVS, and XVZ models:
HCP24781 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 Virago models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3031 OEM front MASTER CYLINDER BASIC REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tube of red rubber brake grease.
$ 84.95
HCP1695 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for all XJ650 Maxim and Midnight Maxim models, 1981 XS1100LH Midnight Special front master cylinder, and XJ1100 front master cylinders, as well as all of the following models: 1983-84 RX50 models, 1987-2000 XV535 Virago models, all 1981-83 XV750 Viragos, and all 1983 XV920 Virago models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tube of red rubber brake grease.
$ 57.95
HCP24780 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3030 OEM front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 119.95
HCP1694 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 69.95
HCP24779 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL Seca, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3032 OEM front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 84.95
HCP1696 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 59.95
for FJ1100, FJ1200, FZ, FZR, FZX, XZ550, and other model calipers:
HCP24779 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL Seca, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3032 OEM front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 84.95
HCP1696 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all non-North American XJ550 models, all 1982 XJ650RJ and RJC Seca models, all XJ650 Turbo models, all non-North American XJ650 models, all XJ700 and XJ750-X models, XJ750P Police (all models), all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, and XJ900RK and RL models. Also fits the following non-XJ models: 1984-85 RZ350, 1983 XZ550 RK Vision, 1984-87 XV700 Virago, 1988-97 XV750 Virago, 1982 XV920J Virago, 1981-82 XV920RH/RJ Virago, 1989-90 FZR1000, 1984-85 XV1000 Virago, and 1986-99 XV1100 Virago models. Each kit contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease,
$ 59.95
HCP24780 Aftermarket front MASTER CYLINDER SEALS AND SPRING KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains both fluid seals, the return spring, the plunger boot and its retainer ring.
$ 39.95
HCP3030 OEM front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 119.95
HCP1694 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT for all North American XJ550 models, as well as the following non-XJ models: 1987 SRZ250, 1988-90 XV250 Route 66, 1995-97 XV250 Virago, 1982-83 XS400 Maxim and Seca models, 1983 XV500 Virago, 1982 XZ550RJ Vision, and 1983-85 XVZ12 Venture models. Contains the piston, both fluid seals, the return spring, the plunger boot and its retainer ring, and a tub of red rubber brake grease.
$ 69.95
HCP29429 OEM front MASTER CYLINDER BASIC REBUILD KIT, for all 1976-77 XS360, 1977-79 XS400, 1980-81 XS400 Specials, 1978-81 SR500, 1976-78 XS500, 1977-79 XS650 Standards, 1978-80 XS650 Special, 1980-81 XS650 Special II, 1981-83 XS650 Heritage and Heritage Special models. Each kit contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease
$ 139.95
HCP26688 Aftermarket front MASTER CYLINDER BASIC REBUILD KIT, for all 1976-77 XS360, 1977-79 XS400, 1980-81 XS400 Specials, 1978-81 SR500, 1976-78 XS500, 1977-79 XS650 Standards, 1978-80 XS650 Special, 1980-81 XS650 Special II, 1981-83 XS650 Heritage and Heritage Special models. Each kit contains the piston, both piston seals, the return spring, shim washer, the plunger rubber boot and its retaining ring, and a tub of red rubber brake grease
$ 39.95
FRONT MASTER CYLINDER RESERVOIRS, RESERVOIR COVERS, and DIAPHRAGMS:
OEM and replacement brake master cylinder RESERVOIRS, COVERS AND DIAPHRAGMS perfectly replace your incorrect, damaged, or corroded pieces perfectly. A new diaphram should be fitted whenever the original is damaged, or when the master cylinder is rebuilt.
HCP3037 OEM front master cylinder RESERVOIR COVER, brand new top cover plate fits and seals correctly, but no longer has the correct appearance as the original covers (it now looks like a generic cover). Fits all original XJ550 North American all models, XJ650 Maxim and Midnight Maxims, XJ1100 front, and 1981 XS1100LH Midnight Special front master cylinders, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders.
$ 37.95
HCP3034 OEM front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XJ550 North American all models, XJ650 Maxim and Midnight Maxims, XJ1100 front, and 1981 XS1100LH Midnight Special front master cylinders, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Also fits all of the following non-XJ models: 1987 XR250, 1988-90 XV250 Route 66, 1988-07 XV250 Virago, 2008-12 XV250 V-Star, 1985-00 XT350, 1982-83 XS400, 1983 XV500 Virago, 1987-2000 XV535 Virago, 1982-83 XZ550 Vision, 1984-2002 XT600, 1981-83 XV750 Virago, and all 1983 XV920 Virago models.
$ 24.95
HCP11192 Aftermarket front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XJ550 North American all models, XJ650 Maxim and Midnight Maxims, XJ1100 front, and XS1100LH front master cylinders, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders. Also fits all of the following non-XJ models: 1987 XR250, 1988-90 XV250 Route 66, 1988-07 XV250 Virago, 2008-12 XV250 V-Star, 1985-00 XT350, 1982-83 XS400, 1983 XV500 Virago, 1987-2000 XV535 Virago, 1982-83 XZ550 Vision, 1984-2002 XT600, 1981-83 XV750 Virago, and all 1983 XV920 Virago models.
$ 18.95
HCP3038 OEM front master cylinder RESERVOIR COVER, but no longer has the same “old-skool” appearance as the original cover with the bold, raised “YAMAHA” wording (it now looks like a generic cover). Fits all original XJ550 non-North American models, XJ650 Turbo models, 1982 XJ650RJ and RJC Seca, all non-North American XJ650 models, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, XJ750P (24L) models, all XJ900RK RL front master cylinders.
$ 47.95
HCP3035 OEM front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XJ550 non-North American models, XJ650 Turbo models, 1982 XJ650RJ and RJC Seca, all non-North American XJ650 models, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL Seca, XJ750P (24L) models, XJ750P (37H) models, and all XJ900RK Seca and XJ900RL front master cylinders, as well as the following non-XJ models: 1985-87 XV700 Virago, 1988-97 XV750 Virago, and 2001-05 FZ1000 models. Each:
$ 32.95
HCP11193 Aftermarket front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XJ550 non-North American models, XJ650 Turbo models, 1982 XJ650RJ and RJC Seca, all non-North American XJ650 models, all XJ700 and XJ750-X models, all XJ750 Maxim and Midnight Maxims, 1984 XJ750RL models, XJ750P (24L) models, XJ750P (37H) models, and all XJ900RK Seca and XJ900RL front master cylinders, as well as the following non-XJ models: 1985-87 XV700 Virago, 1988-97 XV750 Virago, and 2001-05 FZ1000 models. Each:
$ 22.95
HCP10143 OEM front master cylinder RESERVOIR COVER, brand new top cover plate fits and seals correctly, but no longer has the word YAMAHA on the cover nor the quad raised horizontal bars as did the original. Fits 1984-85 FJ600 and all XJ900N, FN, and F models, as well as the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1986-88 FZ600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
$ 24.95
HCP10144 OEM front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits 1984-85 FJ600, 1986-88 FZ600, 1986-90 YX600 Radian, and XJ900 F, N, FN models, as well as the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 and 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
$ 31.95
HCP19390 OEM front master cylinder RESERVOIR COVER, brand new top cover plate fits and seals correctly, but no longer has the word YAMAHA on the cover. Fits all original 1992-98 XJ600 Seca II models.
$ 24.95
HCP19391 OEM front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original 1992-98 XJ600 Seca II models.
$ 24.95
HCP21064 Aftermarket front master cylinder fluid reservoir COVER AND DIAPHRAM SET, brand new original style metal cover, cover gasket, rubber diaphragm, and cover screws fits and seals as original. Fits all original XS1100 models except 1981 XS1100LH Mdnight Special.
$ 129.95
HCP21058 OEM front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XS1100 models except the 1981 XS1100 Midnight Special models. Also fits all of the following models: 1981-82 TZ250, 1976-77 XS360, 1977-799 XS400, 1980 XS400 SG, 1981 XS400 SH, 1976-78 XS500, 1978-81 SR500, 1977 XS650 D/E006501, 1978 XS650 SE/SE-11, 1979 XS650 SF/2F, 1980 XS650 G/SG, 1981 XS650 H/SH, 1982 XS650 SJ, 1983 XS650 K/SK, 1977 XS750 D/2D, 1978 XS750 E/E_277/SE/SE_31, 1979 XS750 F/SF, and all 1980-81 XS850 models.
$ 26.95
HCP26221 Aftermarket front master cylinder RESERVOIR DIAPHRAM, brand new accordion style rubber diaphram fits and seals as original. Fits all original XS1100 models except the 1981 XS1100 Midnight Special models. Also fits all of the following models: 1981-82 TZ250, 1976-77 XS360, 1977-799 XS400, 1980 XS400 SG, 1981 XS400 SH, 1976-78 XS500, 1978-81 SR500, 1977 XS650 D/E006501, 1978 XS650 SE/SE-11, 1979 XS650 SF/2F, 1980 XS650 G/SG, 1981 XS650 H/SH, 1982 XS650 SJ, 1983 XS650 K/SK,
1977 XS750 D/2D, 1978 XS750 E/E_277/SE/SE_31, 1979 XS750 F/SF, and all 1980-81 XS850 models.
$ 17.95
HCP21063 OEM front mater cylinder BUSHING or SPACER PLATE, this stamped metal plate fits under the cover and above the reservoir diaphram, and reinforces the diaphram shape. Fits all 1978-81 XS1100 models (except 1981 XS1100 Midnight Specials). Also fits all of the following models: 1981-82 TZ250, 1978-81 SR500, 1976-77 XS360, 1977-79 XS400, 1980 XS400 SG, 1981 XS400 SH, 1976-78 XS500, 1977 XS650 D/E006501, 1978 XS650 SE/SE-11/E E006501, 1979 XS650 SF/2F, 1980 XS650 G/SG, 1981 XS650 H/SH, 1982 XS650 SJ, 1983 XS650 SK, 1977 XS750 D/2D, 1978 XS750 E/E_27/SE/SE-31, 1979 XS750 F/SF, and all 1981 XS850 models.
$ 57.95
HCP26289 Aftermarket front mater cylinder BUSHING or SPACER PLATE, this stamped metal plate fits under the cover and above the reservoir diaphram, and reinforces the diaphram shape. Fits all 1978-81 XS1100 models (except 1981 XS1100 Midnight Specials). Also fits all of the following models: 1981-82 TZ250, 1978-81 SR500, 1976-77 XS360, 1977-79 XS400, 1980 XS400 SG, 1981 XS400 SH, 1976-78 XS500, 1977 XS650 D/E006501, 1978 XS650 SE/SE-11/E E006501, 1979 XS650 SF/2F, 1980 XS650 G/SG, 1981 XS650 H/SH, 1982 XS650 SJ, 1983 XS650 SK, 1977 XS750 D/2D, 1978 XS750 E/E_27/SE/SE-31, 1979 XS750 F/SF, and all 1981 XS850 models.
$ 29.95
FRONT MASTER CYLINDER RESERVOIR COVER SCREWS:
mc16) Master Cylinder Reservoir COVER SCREWS: they're always buggered up, and there's never a better time to replace these than now! Offered in a variety of both stock (phillips-drive) and hex-drive configurations, in both plain and stainless steel.
NOTE: Original reservoir cover screws on all models were always black plated. If you wish to retain the original appearance of the screws that we offer that are zinc- or bright-plated, a quick little spray of black paint will fix that.....
HINT: seized or destroyed cover screws can be drilled out using a 5/32nd or 3/16th inch drill bit to carefully drill the head out, and then the cover can be removed, leaving a short part of the threaded shaft of the screw to grab onto with vise grips, etc. for final removal. A good quality 1/4" left-hand (reverse-grab) drill bit can sometimes be successfully used to release stuck fastener screws.
If the screw holes need their threads cleaned or re-tapped, this is what you'll need:
HCP2396 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For use on all XJ-series (except XJ750 Seca and XJ750 Euro models with cable-operated master cylinder) and 1981 XS1100 Midnight Special front master cylinder cover hold-down screws.
$ 9.95
HCP2397 THREAD CHASER AND CLEAN-UP TAP, made from a high-speed titanium nitride coated steel. For use on all XS1100 front master cylinder cover hold-down screws (except 1981 XS1100 Midnight Special models).
$ 9.95
HCP28170 Aftermarket thread tap or EZ-out extractor TAP HANDLE, featuring offset tap handles and fully adjustable head for all m3-m12 size taps and size 0 to ½” extractors. This is the proper way to hold a tap or extractor to insure that the force is directed straight down and doesn’t “wobble” as you are cutting, reaming, or extracting. Much better than using pliers or vise-grips to hold the tool……..
$ 17.95
The following screws fit all of these models: 1981-82 XJ550 all models, all XJ650 (except Turbo) models, 1982 XJ750 Maxims, XJ1100 (front) and XS1100LH (front) models.
NOTE: some 1981-2 XJ550 models may also use these longer screws as specified only for the 1983 XJ550 models. You may wish to measure the overall height of your original screws before ordering. The 1981-2 screws are a total height of 10mm, while the 1983 screws are 12mm in total height. While it is acceptable to use the shorter screw in place of the longer ones, it is not possible to use the longer screws in place of the shorter ones.
HCP3040 OEM front Master Cylinder Reservoir Cover flathead SCREW, flathead phillips-drive, alloy steel with a dark gray phosphate coated finish. Each:
$ 7.95
HCP5891 Aftermarket Master Cylinder Reservoir Cover Plate flathead SCREW, bright zinc-plated alloy steel, flathead phillips-drive. Each:
$ 2.95
HCP5893 Aftermarket Master Cylinder Reservoir Cover Plate flathead SCREW, 18-8 stainless steel, flathead phillips-drive, with a bright finish. Each:
$ 3.95
HCP6572 Aftermarket Master Cylinder Reservoir Cover Plate flathead SCREW, 18-8 stainless steel, flathead phillips-drive, with a black-oxide coated finish. Each:
$ 3.95
HCP6557 Aftermarket Master Cylinder Reservoir Cover Plate flathead SCREW, alloy steel with a black-oxide coated finish, 2.5mm hex-drive head. Each:
$ 2.95
HCP6558 Aftermarket Master Cylinder Reservoir Cover Plate flathead SCREW, 18-8 stainless steel with a bright finish, 2.5mm hex-drive head. Each:
$ 3.95
The following screws fit all of these models: 1983 XJ550 all models, 1984-85 FJ600 front, 1986-88 FZ600, 1986-90 YX600 Radian, 1992-98 XJ600 Seca II models front, all XJ650 Turbo models, all XJ700 models, all XJ750-X models, 1983 XJ750 Maxim and Midnight Maxim models, XJ750RL, XJ750P (24L) models, XJ750P (37H) models, and XJ900RK, RL, and N/FN models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders, as well as all of the following non-XJ models: 1988-90 FZR400, 1986 SRX600, 1986-88 FZ600, 1988-99 FZR600R, 1987 FZ700, 1986-87 FZX700 Fazer, 1985-86 1988 FZ750, 1987-88 FZR750, 1987-88 FZR1000, 1984-85 FJ1100, and 1986-93 FJ1200.
NOTE: some 1981-2 XJ550 models may also use these longer screws as specified only for the 1983 XJ550 models. You may wish to measure the overall height of your original screws before ordering. The 1981-2 screws are a total height of 10mm, while the 1983 screws are 12mm in total height. While it is acceptable to use the shorter screw in place of the longer ones, it is not possible to use the longer screws in place of the shorter ones.
HCP3041 OEM front master cylinder reservoir cover plate flathead SCREW, plain steel with a dark gray phosphate coated finish, phillips-drive. Each:
$ 3.95
HCP6559 Aftermarket front master cylinder reservoir cover plate flathead SCREW, alloy steel with a bright zinc-plated finish, phillips-drive. Each:
$ 1.95
HCP6560 Aftermarket front master cylinder reservoir cover plate flathead SCREW, 18-8 stainless steel with a bright finish, phillips-drive. Each:
$ 2.95
HCP6561 Aftermarket front master cylinder reservoir cover plate flathead SCREW, 18-8 stainless steel with a black-oxide coated finish, phillips-drive. Each:
$ 2.95
HCP6562 Aftermarket front master cylinder reservoir cover plate flathead CAP SCREW, plain steel with a black-oxide coated finish, with a 2.5mm hex-drive head. Each:
$ 1.95
HCP6563 Aftermarket front master cylinder reservoir cover plate flathead CAP SCREW, 18-8 stainless steel with a bright finish, with a 2.5mm hex-drive head. Each:
$ 2.95
The following screws fit all of these models: 1981-83 XJ750 Seca and XJ750 Euro models, which used one short and one VERY long screw. Original screws were unique in that they used a rather wide and LOW crown on the head; all of replacement screws have the same WIDE head feature as original, but a slightly TALLER crown on the head. Fit and function will be as original.
HCP6566 Aftermarket Master Cylinder Reservoir Cover Plate panhead SHORT SCREW, plain steel with a zinc-plated finish, phillips-drive. Each:
$ 1.95
HCP6564 Aftermarket Master Cylinder Reservoir Cover Plate panhead LONG SCREW, plain steel with a zinc-plated finish, phillips-drive. Each:
$ 1.95
HCP6568 Aftermarket Master Cylinder Reservoir Cover Plate panhead SHORT SCREW, 18-8 stainless steel with a bright finish, phillips-drive. Each:
$ 2.95
HCP6565 Aftermarket Master Cylinder Reservoir Cover Plate panhead LONG SCREW, 18-8 stainless steel with a bright finish, phillips-drive. Each:
$ 2.95
HCP6571 Aftermarket Master Cylinder Reservoir Cover Plate socket head SHORT SCREW, 18-8 stainless steel with a bright finish, with a 3mm hex-drive head. Each:
$ 2.95
HCP6570 Aftermarket Master Cylinder Reservoir Cover Plate socket head LONG SCREW, 18-8 stainless steel with a bright finish, with a 3mm hex-drive head. Each:
$ 2.95
The following hardware pieces fits all of these models: 1981-83 XJ750 Seca and XJ750 Euro models front master cylinder. Fit and function will be as original.
HCP2423 Aftermarket brake fluid reservoir-to-master cylinder MOUNTING BOLT, bright 18-8 stainless steel socket head, allen-drive. Use 1 per reservoir on all XJ750 Seca and XJ750 Euro models. Each:
$ 2.95
HCP14283 Aftermarket brake fluid reservoir-to-master cylinder mounting bolt FLAT WASHER, 18/8 stainless steel, required for use with the HCP2423 mounting bolt listed above. Use 1 per bolt. Each:
$ 1.95
HCP319 Aftermarket brake fluid reservoir-to-master cylinder mounting bolt LOCK WASHER, 18-8 stainless steel, for use with the HCP2423 bolt listed above. Each.
$ 2.95
The following screws fit all of these models: 1978-79 XS1100 Standard models.
HCP24361 OEM front master cylinder reservoir cover SCREW, flathead, plain steel with a dark gray phosphate coated finish, phillips-drive. Each:
$ 8.95
The following screws fit all of these models: 1979 XS1100 Special and 1980-81 XS1100 Standard models.
HCP21046 OEM front master cylinder reservoir cover SCREW, flathead, plain steel with a dark gray phosphate coated finish, phillips-drive. Use 4 per cover. Each:
$ discontinued
HCP24389 Aftermarket front master cylinder reservoir cover SCREW, flathead, 18-8 stainless steel with a bright finish, phillips-drive. Use 4 per cover. Each:
$ 1.95
The following screws fit all of these models: 1980-81 XS1100 Special and 1980 XS1100 Midnight Special models.
HCP21047 OEM front master cylinder reservoir cover SCREW, flathead, plain steel with a dark gray phosphate coated finish, phillips-drive. Use 4 per cover. Each:
$ discontinued
HCP24389 Aftermarket front master cylinder reservoir cover SCREW, flathead, 18-8 stainless steel with a bright finish, phillips-drive. Use 4 per cover. Each:
$ 1.95
MASTER CYLINDER FLUID SIGHT WINDOW:
mc2) ) While you're rebuilding or even replacing your front master cylinder, you might as well go ahead and replace that dull, clouded, cracked thick plastic sight "window" that, once upon a time, allowed you to see the level of brake fluid in the reservoir. The original "transparent" round plastic window ages neither gracefully nor well over time, and becomes cloudy within a few years. Our replacement windows are available either as an original-style replacement plastic window (complete with rear metal “anti-splash” disc), or for a longer lasting, clearer view, as a flat mineral glass window that is the correct size (and unlike the plastic windows, the glass windows won't ever get cloudy). Both are one of those small details that you can step back, look at, and say to yourself: "Kewl".
Okay, all that's the good news. The bad news is that the old plastic window and --- in the case of the replacement plastic windows, the metal ring --- can be a beast to remove. Sometimes, they come out all nice and easy. Sometimes, you have to do battle, and as that classic old Pink Floyd song suggests: "One of these days, I'm going to cut you into little pieces......". You get the idea. You'll have to fight, struggle, and then win.
The replacement plastic windows will all show a small amount of “haze” and/or surface “scratches” due to the manufacturing process, and, like the original plastic windows, will again cloud up over time; while the replacement glass windows require a little more effort to install, the result is a much higher quality and longer-lasting appearance. Replacement glass windows come with illustrated install instructions.
Our HCP15662 radial disc brush will make the cleaning and polishing of the "seat" area (where the new sight window will be installed) a simple task for the installation or either type window.
Here is a good video showing the basic (generic) installation of a sight window:
www.youtube.com/watch?v=F_yo3FnH6DM
Replacement Plastic Fluid Level Windows:
These windows will only fit the later “Style A” original front master cylinder reservoirs, but we’ve found that on some original master cylinders, the bore hole in the reservoir body (where the sight window is fitted), may not be quite dimensionally correct…..which is why the metal “trim ring” or fitting ring was used, to take up any very minor differences in order to insure a tight, leak-proof fit. Since you will need to remove this fitting ring in order to install these plastic windows……..they come with a bonded fitting ring already installed onto the plastic window…..you should be aware that the removal process can be a challenge, and, you may need to clean and/or perform a minor re-sizing of the bore opening to get a fit of the replacement window into the cavity. Most times, we can heat up the m/c reservoir gently with a heat gun, etc. which expands the bore cavity just enough to make installation of the new window easy enough (but, don’t be surprised if you still need to “drive” the sight window in, using a piece of wood against the face of the window and gently hammering it on home………).
These plastic windows are a lower-cost option than our flat glass windows, but they too will eventually cloud over (5+ years) like the originals did.
Here’s the difference between an “A” and “B” style original master cylinder (and their sight windows)::
http://www.xj4ever.com/choosing a sight glass.pdf
HCP27626 Aftermarket front brake master cylinder glass brake fluid level SIGHT WINDOW, correct size and thickness plastic window with bonded outer metal “fitting band” and rear anti-splash disc……just like original. NOTE: fits all Style A front master cylinders, and all XJ1100 and 1981 XS1100LH Midnight Special rear master cylinder fluid reservoirs. Requires the removal of the original pressed-in metal “fitting band” in the reservoir body, but does not require the use of gasket maker/adhesive for installation. Includes a replacement cavity o-ring. Each:
$ 7.95
Replacement Glass Fluid Level Windows:
Our replacement precision-ground flat mineral glass window is a simple and durable upgrade to the original style plastic windows, and are “glued” in place with an RTV adhesive that will stand up to brake fluids. Although there are probably lots of brands of gasket-maker/sealant material that will work, we've found one that is black, easy to work with, and is impervious to brake fluid (NOTE: if you're going to try to use some gasket material that you have sitting around, make DARN SURE that you test it to see whether brake fluid attacks it or prevents it from hardening (almost none of the major gasket-maker materials have been "tested" by their manufacturers against brake fluid, since you do not normally ever use gasket-sealant material in a brake system).
Note that our replacement glass windows do not require the removal (nor should you!) of the original metal “fitting ring/band” that is pressed into the reservoir body.
NOTE: There are two different types of master cylinders that were used on XJ-series bikes.....externally, they both look the same and are marked identically on the outside, so there is no way to tell them apart in that regard. But they differ greatly in the manner in which their SIGHT WINDOW was attached, and also in the size of the sight window used:
a) Master Cylinder Style A has a PRESSED-IN sight window, and would use our replacement HCP1074 glass sight window.
Identification: this style of original plastic sight window mounts completely flush with the outside of the master cylinder body, and is fitted into a very thin, pressed-in metal bushing that is visible on the external face of the master cylinder. Inside of the master cylinder reservoir, there is no visible part of the sight window present, and there is usually a thin metal disc with a thin slot cut into it that is behind the sight window.
b) Master Cylinder Style B has a C-CLIP retained sight window, and uses a rubber o-ring to seal the sight window to the body of the master cylinder reservoir, to prevent fluid leaks from around the sight window. This style master cylinder will use the HCP9819 replacement glass sight window.
Identification: this style of original plastic sight window protrudes out, away from the external face of the master cylinder body, by about 1/8". And on the inside the master cylinder reservoir, there is a large u-shaped metal clip that retains the plastic "snout" of the plastic window.
We do offer a visual guide that helps you to properly identify which style master cylinder (and thus sight window) that your master cylinder is equipped with; please review this to help you determine which one you need:
http://www.xj4ever.com/choosing a sight glass.pdf
and
https://www.xjbikes.com/forums/threads/1985-86-xj700-caliper-rebuild.118121/page-2
For the Style "A" Master Cylinders:
HCP1074 Aftermarket front brake master cylinder glass brake fluid level SIGHT WINDOW, correct size and thickness crystal-clear mineral glass. NOTE: fits all Style A front master cylinders that have a pressed-in original sight window, and all XJ1100 rear master cylinder fluid reservoirs. Does NOT fit original front master cylinders that have an o-ring and c-clip retained sight window. Each:
$ 11.95
HCP17201 Aftermarket sight window O-RING. For use ONLY with original master cylinders that use a pressed-in plastic sight window. This is the o-ring that seals the sight window bushing to the inside of the master cylinder body. If your master cylinder is leaking or weeping fluid from the sight glass area, this is what you need to replace. Good idea to replace this item as a precaution during a master cylinder rebuild, but, you must remove the original sight window to access it (which typically destroys the original sight window!), so it's a Catch-22 situation. Although you can use this o-ring with our replacement HCP1074 glass window, it's not really necessary (since the replacement glass window will be glued in place).
$ 3.95
For the Style "B" Master Cylinders:
HCP9819 Aftermarket front and rear brake master cylinder glass brake fluid level SIGHT WINDOW, correct size and thickness crystal-clear mineral glass. NOTE: fits all style B front master cylinders that use a c-clip retained original sight window, and fits the 1981 XS1100LH Midnight Special rear master cylinders. Each:
$ 11.95
HCP9830 Aftermarket sight window O-RING. For use ONLY with original master cylinders that use a c-clip retained plastic sight window. This is the o-ring that seals the original plastic sight window to the inside of the master cylinder body; it is not needed when replacing this style master cylinder sight window with our replacement HCP9819 sight glass. If your master cylinder is leaking or weeping fluid from the sight glass area, and you continue to use the original plastic sight window, this is what you need to replace. Good idea to replace this item as a precaution during a master cylinder rebuild.
$ 3.95
Sight Window Installation Supplies:
HCP3120 Aftermarket black GASKET MAKER, large family-sized 3.8 ounce squeeze tube. Enough to install about a thousand glass sight windows! I'm sure it works well in other applications. Needed for use when installing our replacement glass sight windows. Not necessary when using our replacement plastic window. Each:
$ 12.95
HCP3120A Aftermarket black GASKET MAKER, smaller 1/2-ounce squeeze tube. Enough to install about a hundred glass sight windows! It's the smallest size offered. I'm sure it works well in other applications. Needed for use when installing our replacement glass sight windows. Not necessary when using our replacement plastic window. Each:
$ 8.95
HCP15662 Aftermarket RADIAL DISC BRUSH KIT, contains a properly sized miniature abrasive "flap" brush that is both small enough and abrasive enough to remove glue remnants and rust that is common in the sight window seat flange area.............the flat area where your new glass sight window needs to seat and seal against (when using our glass window) or the fitting ring land (after the original fitting ring is removed; when using our replacement plastic sight window). The 3/32" shank fits into most standard drill chucks (or dremel tools that have a properly sized collet) and allows you to make quick work of the polishing of this area before the installation of your new sight window.
$ 16.95
FRONT MASTER CYLINDER FLUID LEVEL SENSOR:
HCP3022 OEM master cylinder FLUID LEVEL SENSOR. This is the complete low-brake-fluid sensor switch assembly: float, post, lead wires and connectors. For all 1982 XJ750 Maxim front and XJ1100 front master cylinders.
$ 129.95
HCP3025 OEM master cylinder FLUID LEVEL SENSOR. This is the complete low-brake-fluid sensor switch assembly: float, post, lead wires and connectors. For all XJ750 Seca front and XJ1100 rear master cylinders.
$ 149.95
HCP19573 Aftermarket LOW-FLUID SENSOR BY-PASS WIRE, for low-brake fluid sensor. If your sensor is not functioning or missing, you'll need to by-pass the sensor so that the computer is fooled into thinking there is plenty of fluid in the reservoir. (and to stop flashing the dash warning light at you!). For use on all XJ650 Turbo models, 1981-83 XJ750 Seca models and XJ750 Euro models, and 1982 XJ750 Maxim models. Simple plug-and-play operation.
$ 12.95
HCP3023 OEM front master cylinder reservoir float sensor shaft O-RING, where the fluid level sensor wires exit the reservoir chamber, for all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders. Use 1 per master cylinder.
$ 12.95
HCP16194 Aftermarket front master cylinder reservoir float sensor shaft O-RING, where the fluid level sensor wires exit the reservoir chamber, for all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders. Buna-N material like original. Use 1 per master cylinder.
$ 6.95
HCP16193 Aftermarket front master cylinder reservoir float sensor shaft O-RING, where the fluid level sensor wires exit the reservoir chamber, for all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders. Tough Viton material. Use 1 per master cylinder.
$ 8.95
HCP4257 OEM front master cylinder fluid level sensor retaining E-CLIP, for all XJ750 Seca and XJ750 Euro models. This is the large circlip on the bottom of the reservoir.
$ 2.95
HCP22312 Aftermarket front master cylinder fluid level sensor retaining E-CLIP, for all XJ750 Seca and XJ750 Euro models. This is the large circlip on the bottom of the reservoir. Black oxide coated alloy steel. Each:
$ 1.25
HCP22313 Aftermarket front master cylinder fluid level sensor retaining E-CLIP, for all XJ750 Seca and XJ750 Euro models. This is the large circlip on the bottom of the reservoir. Bright 18-8 stainless steel. Each:
$ 1.95
HCP6836 OEM front master cylinder fluid level sensor retaining E-CLIP, bright plated spring steel. This is the small clip that retains the float, at the very top of the shaft. For all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders.
$ 7.95
HCP905 Aftermarket master cylinder fluid level sensor retaining E-CLIP, black-phosphate coated spring steel as original. This is the small clip that retains the float, at the very top of the shaft. For all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders.
$ 47.95
HCP2909 Aftermarket master cylinder fluid level sensor retaining E-CLIP, type 420 stainless spring steel. This is the small clip that retains the float, at the very top of the shaft. For all XJ650 Turbo, XJ750 Seca, XJ750 Euro, 1982 XJ750 Maxim, XJ750-D, XJ750P (24L and 37H) models, and XJ1100 front and rear master cylinders.
$ 6.95
HCP4190 OEM brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Zinc-plated steel, panhead phillips-drive. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 6.95
HCP6418 Aftermarket brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Zinc-plated steel, panhead phillips-drive. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 1.95
HCP6420 Aftermarket brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Bright 18-8 stainless steel, panhead phillips-drive screw. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 1.95
HCP6421 Aftermarket brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Bright 18-8 stainless steel, small-head (JIS) panhead phillips-drive like original. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 3.95
HCP6422 Aftermarket brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come without the lock washer or the flat washer, which must be ordered separate below. Black-oxide coated 18-8 stainless steel, panhead phillips-drive screw. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 2.95
HCP6644 Aftermarket brake fluid level sensor MOUNTING SCREW. Originally it had a captured lock washer and flat washer; these replacement screws come with the lock washer but without the flat washer, which must be ordered separate below. Yellow zinc-plated steel, panhead phillips-drive screw. Use 1 on all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders. Each:
$ 1.95
HCP326 OEM brake fluid level sensor mounting screw LOCK WASHER, for all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders.
$ 3.95
HCP922 Aftermarket brake fluid level sensor mounting screw LOCK WASHER. Zinc-plated alloy steel, each:
$ 1.95
HCP336 Aftermarket brake fluid level sensor mounting screw LOCK WASHER. 18-8 stainless-steel, each:
$ 2.95
HCP342 Aftermarket brake fluid level sensor mounting screw LOCK WASHER. Black oxide-coated steel, each:
$ 1.95
HCP328 OEM brake fluid level sensor mounting screw FLAT WASHER, for all XJ650 Turbo, 1982 XJ750 Maxim, and XJ750P (24L), XJ750P (37H), and XJ1100 front master cylinders.
$ 3.95
HCP924 Aftermarket brake fluid level sensor mounting screw FLAT WASHER. Zinc-plated, alloy steel, each:
$ 1.95
HCP338 Aftermarket brake fluid level sensor mounting screw FLAT WASHER. 18-8 stainless-steel, each:
$ 2.95
HCP28050 Aftermarket brake fluid level sensor mounting screw FLAT WASHER. Grade 316 stainless-steel, each:
$ 3.95
HCP1356 Aftermarket brake fluid level sensor mounting screw FLAT WASHER. Black oxide-coated steel, each:
$ 1.95
FRONT MASTER CYLINDER BRAKE LIGHT SWITCH:
NOTE: except on the XJ750 Seca models, the removal of these switches from the master cylinder housing seems like a trick Chinese puzzle, until you figure it out.....there is small, round hole (about 2mm diameter) on the forward side of the housing where this switch plugs in. Using a small screwdriver or other such object, gently push in through this hole onto the plastic "tooth" that is part of the switch housing, while also pulling back on the switch. Releasing this ratchet tooth will release the switch from the housing, and out it comes! Here's a good image of it:
http://xjbikes.com/forums/index.php?threads/38144
HCP441 OEM front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch snaps into the master cylinder housing and includes the correctly colored wire harness leads and connector. Fits all of the following models using original master cylinders: XJ550 all models, XJ650 all models, XJ750 Maxim and Midnight Maxim models, XJ750P (37H model), all XJ900RK and RL models, XJ1100, and all XS1100 models, and also fits our aftermarket HCP3063WO and HCP1808WO master cylinders.
$ 69.95
HCP3522 Aftermarket front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch snaps into the master cylinder housing and includes the correctly colored wire harness leads and connector. For the following models: XJ550 all models, XJ650 all models, XJ750 Maxim and Midnight Maxim models, XJ750P (37H model), XJ900RK and RL models, XJ1100, and all XS1100 models, as well as our aftermarket HCP1808WO and HCP3063WO master cylinders . A very nice reproduction of the original. NOTE: the length of the lead wires on this switch are 9" shorter than on the original HCP441 switch.....please determine whether this difference in length is going to cause any problems with proper installation or use on your model bike (especially at the full left or right handlebar lock positions).
$ 39.95
HCP19392 OEM front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch snaps into the master cylinder housing and includes the correctly colored wire harness leads and connector. For the following models: all 1992-98 XJ600 Seca II models.
$ 34.95
HCP442 OEM front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch snaps into the master cylinder housing and includes the correctly colored wire harness leads and connector. For the following models: all XJ700 and XJ750-X models.
$ 43.95
HCP3413 OEM front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch screws into the brake lever housing and includes the correctly colored wire harness leads and connector. For the following models: XJ750 Seca models.
$ 79.95
HCP13777 OEM front master cylinder BRAKE LIGHT SWITCH, complete with lead harness. This small black plastic cylinder plunger switch screws into the brake lever housing and includes the correctly colored wire harness leads and connector. For the following models: FJ600 and all XJ900 N, FN, and F models.
$ 37.95
HCP3556 OEM brake light switch MOUNTING SCREW, for use on all XJ750 Seca and Euro models, use 1 per bike, each:
$ 2.95
HCP2908 Aftermarket brake light switch MOUNTING SCREW, black-oxide coated steel, for use on all XJ750 Seca and Euro models, use 1 per bike, each:
$ 1.95
HCP13788 OEM brake light switch MOUNTING SCREW, for use on all 1984-85 FJ600 models, use 1 per bike, each:
$ 7.95
HCP3633 OEM brake light switch MOUNTING SCREW, for use on all XJ900 N, FN, and F models, use 1 per bike, each:
$ 2.95
HCP23024 Aftermarket brake light switch MOUNTING SCREW, for use on all XJ900 N, FN, and F models, use 1 per bike, zinc-plated alloy steel as original, each:
$ 1.95
HCP23025 Aftermarket brake light switch MOUNTING SCREW, for use on all XJ900 N, FN, and F models, use 1 per bike, 18-8 stainless steel, each:
$ 2.95
HCP4458 OEM brake light switch screw FLAT WASHER, for use on all XJ900 N, FN, and F models, use 1 per bike, each:
$ 2.95
HCP924 Aftermarket brake light switch screw FLAT WASHER. Zinc-plated, alloy steel, each:
$ 1.95
HCP338 Aftermarket brake light switch screw FLAT WASHER. 18-8 stainless-steel, each:
$ 2.95
HCP28050 Aftermarket brake light switch screw FLAT WASHER. Grade 316 stainless-steel, each:
$ 3.95
HCP1356 Aftermarket brake light switch screw FLAT WASHER. Black oxide-coated steel, each:
$ 1.95
BRAKE HOSE HARDWARE:
These union bolts and precision sized copper crush washers are used to seal the brake hose end fitting to the master cylinder fluid outlet port. Each union bolt requires the use of two crush washers. Crush washers should be replaced every time you remove a brake hose!! NEVER use any other type of washer in place of a crush washer!!!
HCP1075 OEM brake hose junction UNION BOLT, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt. Black finish, is used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 19 foot-pounds of torque! Crush washers are not included and should be ordered separate. Each:
$ 8.95
HCP4232 Aftermarket brake hose junction UNION BOLT, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt. Large-head design, bright finish, made from 18/8 stainless steel. Used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 15 foot-pounds of torque! Crush washers are not included and should be ordered separate. Each:
$ 9.95
HCP21321 Aftermarket brake hose junction UNION BOLT, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt. Dark phosphate-coated finish, is used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 19 foot-pounds of torque! Crush washers are not included and should be ordered separate. Each:
$ 6.95
HCP29039 Aftermarket brake hose junction UNION BOLT, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt. Bright zinc-plated finish. Used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 19 foot-pounds of torque! Crush washers are not included and should be ordered separate. Each:
$ 6.95
HCP24129 Aftermarket brake hose junction UNION BOLT, used to attach a brake line end fitting to the master cylinder, distribution block, caliper, or lower fork tube anti-dive valves. This is a single-hose-attachment length bolt. Highly polished chrome finish. Used on all models, in all positions, except for the models/positions listed as using a double-hose-attachment length bolt under part number HCP1076 below. These bolts should be tightened to a maximum of 19 foot-pounds of torque! A pair (2) of crush washers are included. Each:
$ 9.95
HCP1077SET2 OEM brake hose union bolt copper CRUSH WASHERS, pair:
$ 14.95
HCP4231SET2 Aftermarket brake hose union bolt copper CRUSH WASHERS, pair:
$ 6.95