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

[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... =)

[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-...1cbb8d&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.