READ THIS!!!!!!! Honda 200x 350x rear brake master cylinder secret

[Timmy]

Hey all you three wheeler world nuts!!!! If you have a Honda 350x, or 200x, I have a secret for you. I decided to reveil this because I know how you feel if you have a stuck rear brake master cylinder.

First step is to get that cylinder unstuck well you need a drill, drill bit, vise, screw driver, small screw with coarse threads, and a slide hammer.

Second take out the snap ring with a pick or snap ring pliers.

Third drill a hole straight down the center of the piston. Warning this must be straight!!!!! make sure the drill bit is not to big for the screw you are going to use to put in the piston after the hole is drilled.

Fourth install the screw in until the head is slightly above the piston bore you can now use two screwdrivers and pry on each side to get the piston out slowly but surely just be patient and try really hard not to damage to bore.

Fifth take a wire clothes hanger and a scotch brite pad, cut about a six inch piece off and fold it in half, rip off a small piece of the pad and stick it between the hanger you just folded and chuck it up in your drill, try to get it centered.

Sixth lube the piston bore with lots of WD 40 install the contraption you just made with the hanger and pad. use this to clean up, hone the bore, use a slight in and out motion.

Now for the biggest secret a kit for this I searched long and hard and found this buy a kit for one of the following found mine on ebay. for about 35.00 much cheaper than trying to buy one that works this forum will expire soon!!

CB1100F Supersport (83)
VF1100C V65 Magna (83-86)
CBX (81-82)
CB1000C Custom (83)
CB900C Custom (81-82)
CB900F Supersport (81-82)
CB750F Supersport (81-82)
CX650T Turbo (83)
CX500TC Turbo (82)
FT500 Ascot (82-83)

Please keep this secret to us 3wheeler freaks :w00t:

[Solid Snake]

Interesting indeed, I bookmarked this thread in case I ever need to fix my rear master cylinder. Thanks for the compatibility info.

[200x Basket]

i have a better way to remove a stuck piston if you have two bikes. fill the stuck master full of fluid. then remove the hose from a good caliper and connect it to the stuck master. now push the brake on the working system. pop goes the stuck piston.

[dreadhed]

You can also use compressed air to blow the pistons out. Just put a air hose on the end of the line. From what I under stand you should not use and petrol based lubes only brake cleaner.

[Dirtcrasher]

If the brake assembley is still on the trike you can crack the bleeder at the caliper, put a grease gun on there and force the master cylinder piston out that way. It must be mounted on the trike though or the caliper piston will come out....

I'd drill it as a last resort but still a good suggestion Timmy....Thanks for the "Secret" ....

[Timmy]

Thanks for all the great tips. I had to use the drilling as a last resort mine was stuck so hard that was the only way to bring it out one of my co workers suggested hooking up another master cylinder to it and I hooked it to my front one and tried compressed air but drilling was it. Also it don't matter if you ruin the piston, a new piston, seals spring and boot all come with the kit if you buy the kit with the right boot some have a differen't style boot so look at a pic and make sure its the same before you buy it thanks everyone:beer

[XTRM-NRG]

Hello Timmy,
I purchased the rear master brake cylinder rebuild kit that you recommended from E-bay and it DOES NOT WORK. The cross referenced motorcycle list that you posted was exactly the same list that the ebay seller posted on his item description. I double checked the ebay master cylinder rebuild kit item number that I ordered from him and its fits the same motocycles that you listed.
Anyway, the piston is too large as it does not fit into the bore of the master brake cylinder main body. The piston design is also slightly different. I purchased the kit on Ebay from "Cyclepartsdirect". The kit number is #08-0212 and is made by "Tour Max". As I said, the Ebay seller listed the cross referenced motorcycles Exactly in the same order that you posted in your thread, so I was certain this was the master rebuild kit and probably the same seller that you purchased from.
Could you let me know who manufactured your 350X rear master cylinder rebuild kit, the stock number and the Ebay seller? Maybe I was sent the wrong kit? :wondering
Also, the OEM 350X rear master cylinder rebuild parts are not available from Honda anymore! Thanks Jett

[Saul]

Timmy had 5 posts in 2007 - somehow I'm betting Timmy isn't here anymore. :)

[XTRM-NRG]

Yikes! Thanks Saul.....I didn't realize to look at the date that Timmy posted the thread. Anyway, I am out 35 dollars and I can't find a rebuild kit!,,,,:(

[harryredtrike]

one more tool in the arsenal

[XTRM-NRG]

I noticed that Timmy had a photo of a 1986 350X posted with this thread. Well, you know the small changes that honda made to the 1986 from the 1985 350X. I thought, Honda may of possibly changed the master brake cylinder design of the 1986 350x, so maybe that is why the kit Timmy recommended does not fit? I looked up the part numbers and AAuuugh! :eek: 1985 and 1986 use the same rear master cylinder!! I am going to a friends house and check his 04 Honda 400ex. Maybe the 400ex's rear master brake cylinder is somehow combatible with our 350x's. My search begins!!!!

[Dirtcrasher]

I wonder why the front can be found, but not the rear??

http://www.hyperparts.com/wc.dll?ctwp~getitemclass~1001~1002~1~part~H133101

Gotta be something.....

[SWIGIN]

i have a better secret to fixing old seized master cylinders.....throw them out and use one from a newer bike or quad.

[torker]

i have a better secret to fixing old seized master cylinders.....throw them out and use one from a newer bike or quad.


Exactly what he said...And they're cheap too.
TORKER.

[zachgraves]

I just got a 85 350x and have been doing a lot of work on it. Now im at the back breaks and my rear master cylinder is locked up. I would rather buy a new one then fix the old one but wasnt real sure what all fit and if some fit better than others? My buddy has a 400ex and it looks like it would fit but i just wasnt real sure. :wondering

[XTRM-NRG]

Today I was kneeling between my 85 350X and my 06 Kawasaki KLR650 staring at the 350X's master cylinder that I disassembled and cleaned. I was measuring the eye to eye width of my 350X's rear master cylinder, when I just happened to glance over at the KLR's rear Master brake cylinder. I notice that the master cylinder mounting holes were almost the same width and when I measured with a Micrometer I confirmed the holes were both equally spaced at 2 inches apart. Then I put the 350X's master brake cylinder next to the KLR's and I was surprised that the KLR's Master cylinder might work with the 350X!!! I temporarily removed my KLR's rear brake system to do a rough fit of the rear master cylinder and to my surprise it fit almost perfectly to the 350X's frame!!! The only problem I see is that the nipple that connects to the brake res. hose is bent 90 degrees instead of straight back. I still need to check out my friends 04 400ex's master brake cylinder. I will give an update once I figure out if the 400ex master cylinder will also fit..

[SWIGIN]

yup, they are all pretty close to fitting. worse case you need to make a simple plate to mount it to like i did in this pic.

i used one from a yzf400-450 dirt bike and the nipple that you say is angled wrong on this one piviots so i can aim it anywhere i need it.

another thing to remeber is that the rod sticking out of the bottom can be swaped out as well.

[Dirtcrasher]

^ What holds your nipple from falling out? It appears like it's tipping out in your picture....

[XTRM-NRG]

I just came back from my friends house who owns a 04 Honda 400ex. I measured the eye to eye spacing on the 400ex's master cylinder and it is 1 3/4 inches apart. But like "SWIGIN" said, all you have to do is fabricate a simple mounting plate and the 400ex's master brake cylinder will match up very close to stock. I am going to find a KLR master brake cylinder on Ebay cause I know that will bolt up without any modifications....I will let you guys know what happens when I am finished...Thanks for posting a picture of your fabricated YZF master cylinder!!

[XTRM-NRG]

Well, I finally had some time to complete my rear master brake cylinder replacement on my 85 350X. I ended up purchasing a 2007 Kawasaki Ninja 650R rear master brake cylinder, brake fluid reservoir and reservoir hose that I purchased off Ebay for around $25. The master brake cylinder bolts right up to the 350X frame using the stock bolts, but you need a couple of washers to position the rear master brake cylinder directly over the OEM brake "V" lever pivot mechanism that pushes straight up into the master brake cylinder when you depress the rear brake pedal. (See Pics) You also need to cut (shorten) and re-thread with a tap/die set the rear brake pedal adjustment mechanism, because it is too long to use without modification. (See Pics). You can cut and reuse the Ninja 650's super long brake reservoir hose and reconnect it to the 350X's OEM brake fluid reservoir. (You will not use the Ninja 650's brake fluid reservoir.) You also have to order a new rear brake line that is approx. 2 inches longer than stock. I ordered a DOT rated 2 inch longer than stock rear braided steel brake line on Ebay for $25 + shipping and it fit just right. After I connected everything I made sure nothing was binding or rubbing against the muffler when I cycled the rear suspension. Then I bled the rear brake system and the rear brakes now work better than before!!!.... Hope this helps... =)
http://farm3.static.flickr.com/2756/4113710507_b84a224115_m.jpg
http://farm3.static.flickr.com/2567/4114479716_e2ca5b4b07_m.jpg
http://farm3.static.flickr.com/2490/4113710439_afc516ed5a_m.jpg
http://farm3.static.flickr.com/2486/4113710659_55b937ce7c_m.jpg

[captainweezy]

Bump for a good piece of info.
I just got done searching for a compatible rear master for my 85 350x. I finally came up on this thread. So I am off to eBay to get a Kawasaki rear master. If anyone else knows what other rear masters will work, post up here or I think there is a member trying to put up a website for parts compatibility right now. Did anybody ever find out if a 400ex master was the same?

[honda200x1987]

Bump for a good piece of info.
I just got done searching for a compatible rear master for my 85 350x. I finally came up on this thread. So I am off to eBay to get a Kawasaki rear master. If anyone else knows what other rear masters will work, post up here or I think there is a member trying to put up a website for parts compatibility right now. Did anybody ever find out if a 400ex master was the same? There is a new aftermarket complete assembley out there http://www.ebay.com/itm/NEW-ATC350X-350X-85-86-REAR-MASTER-CYLINDER-/271088139149?pt=Motors_ATV_Parts_Accessories&hash=item3f1e1cbb8d&vxp=mtr

[captainweezy]

Yes I saw that but at $90? Compare that to the Kawasaki ninja above that EXTR-NRG found. I found one for $10 plus shipping.

[duck4twenty]

So who do I remove my stuck MASTER CYLINDER not calipers I'm stuck trying to figure out how to remove my master cylinder

[shortline10]

I use a grease gun were the banjo bolts in and pump away , haven't had one I couldn't remove yet , my grease gun threads in perfect .



So who do I remove my stuck MASTER CYLINDER not calipers I'm stuck trying to figure out how to remove my master cylinder

[sanchez]

Grease gun excelent better than ideas from the peanut gallery back when.
But will not work on fixed caliper with duel opposed piston instead of drilland tap i tig welded nuts in the calliper piston

[Leevvii]

Bump for a good piece of info.

Thanks, i got stuck pistons on 200X [both], and the rear master cylinder piston also. I'll try anything!.

[Onetrackmind]

Have you gotten the pistons freed Leevvii? If the grease gun or compressed air doesn't work for any or all of them, try going the other way first.

I have had good luck by pushing the Pistons back in slightly with a vice or C clamp first, then blowing them out with the compressor. Sometimes any movement at all (even in the wrong direction) is all it takes.

Good luck.

[Leevvii]

thanks mate, i tried compressed air, one moves outwards but only about 1/4", wont go the rest the way. The other is stuck level with the caliper block, it wont budge. Will hooking up the brakes and using the fluid pressure to push them out[in reverse fluid direction if nessasary], work in this case? opinions?

The rear master cylinder can take a screw into the piston [to lever it out] , but can the caliper pistons handle drilling to take a screw? ie- and not penetrate through the piston?

A question - What is the purpose of the rubber "boots" around the bolts that the bracket mounts onto?

[Onetrackmind]

You can definitely try it, but I would think that either grease or compressed air would be your best bet. What PSI are you getting from your compressor? It takes quite a bit (100psi in my case).

I haven't ever drilled a piston, so someone else will have to weigh in on that one.

I think you are referring to the slider pin bushings. If so, those keep debris out of the slider pins. The slider pins should be able to slide freely ...allowing the caliper to move when actuating the brakes.

[yaegerb]

Compressed air everytime for me. I take my compressor regulator up to 150 and they blow right out.

[Leevvii]

great news , i got the rear master cylinder "unstuck", its all apart now, comp air done the trick, and the cylinder cleaned up really well. I want to buy a new seal kit, but i notice the Shindy brand kit is only for the 86/87 200x, so im assuming that the rear master cylinders are different on the gen 1 200x, is this correct? Anyone know of any kits that fit the gen 1 200X?

[jb2wheels]

I used a rear master rebuild kit for a TRX250EX/TRX300EX/LTR450Z from Moose PN MD06-051 when I rebuilt the stock rear master on (what used to be) my 86 350X

The seals are the right size. I have pictures on my phone somewhere...

The rubber cup for the outside is wrong but can work.
You can still buy the right piece from Honda BOOT, MASTER CYLINDER 43504-371-013

[oldskool83]

Air compressor nozzle in bleeder hole. Bolt in banjo hole...wait 29 seconds and it will sound like rifel. End or story....and I only have an associate's degree!

[jb2wheels]

Pictures:

Stock 86 rear master is 1/2" bore:
253153

The Moose Kit:
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Side by side compare:
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The Moose cup installed:
253149

The OEM Cup
253150

For reference - the open lip faces up:
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This one too:
253147