You might concider upgrading to the 2005 master cylinder as mentioned earlier. I have had no trouble with mine.

 

I can let you know next week as mine should be here Thurs or Friday.

 

Not sure if this will help or not but I do know of someone who had a similar problem and they were using DOT 3 brake fluid. They used DOT 4 as the service manual suggested and their problem was fixed.

I do not know the difference between Dot 3 and DOT 4 brake fluid. I believe one is rated for a higher temp than the other so it could have a higher viscosity or something.

SJ

 

Now that Swampy mentioned it I too remember that Dot 4 is required for a reason.

 

I used DOT 4 and had no luck. All the parts to swap to a 2005 system was only 200 bucks, I think the master cyl for the 2004 was nearly that much by itself.

 

pretty sure that the master cylinder is gone. I unhooked the brake line from it, took it right off the bike, filled it with fluid and pumped on the shaft --- no pressure built up.
There seems to be lots of play in the shaft and I noticed small air bubbles come out from around the rubber boot.
also, I was already using DOT 4


thanks everyone for your input
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