The bike came with some temporary small chinese master brake cylinder. It did work but the braking power was minimal. I guess putting my foot on the asphalt would have the same braking power...
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| Honda CB500K1 temporary master cylinder |
Luckily the old clogged up master brake cylinder came as a spare part with the bike. It was completely stuck and was in desperate need of a rebuild.
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| Honda CB500K1 master cylinder |
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| Honda CB500K1 master cylinder exploded view |
So I bought a rebuild kit for around 25 dollar from 4into1.com and started the rebuild.
It looks easy but it can be a real pain to get all the old rusted, clogged parts out of the mater brake cylinder.
The biggest challenge was to get the retaining clip out. It sits quite deep in the narrow shaft and most tools are too fat to reach it. The best option is to use a pick or similar. For more than an hour it wouldn't move even a nano inch but then all of a sudden it snapped into 3 pieces and I finally could take it out. All the other pieces are now easy to remove.
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| Honda CB500K1 master cylinder old bits |
I gave the master brake cylinder a good clean and sanded the inside with 240 and then 400, 600 grid and finally some steel wool to get rid of most of the corrosion.
The rebuild kit comes with some red grease which should be applied to the new rubber bits. Of course the new retaining spring gave some trouble... I pushed it in all the way with a long socket that just fits inside the narrow master brake cylinder entrance. There's a small groove in which the clip should click in.. It looked like it clicked in the groove but apparently it wasn't and everything got stuck inside, grrr...
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| Honda CB500K1 master cylinder rebuild kit |
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| Honda CB500K1 master cylinder rebuild |
After some trial and error ther clip came out and in the second attempt I managed to get it click into its groove.
I also ordered a new cap as the old one was faded and damaged on the outside, and of course a new diaphragm. The plastic ring that goes between the cap and the diaphragm was still in perfect condition so I reused it.
Another little thing I had to replace was number 11 (part 45526-341-000) in the exploded view. It's a rubber/plastic tube and a piece of fishtank hose was a perfect fit ;)
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| Honda CB500K1 master cylinder bush 45526-341-000 |
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| Honda CB500K1 master cylinder rebuild |
All done :)
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