Ok, now have any tips/tricks on rebuilding the master cylinder? I think I will just get the parts seprate vs a kit like on Ebay.

 

First I would pull out the old piston and seals and check if the master cylinder body is corroded inside! If it is I would replace it with the updated master cylinder! I tried a lot of times to try to clean up the corrosion with small ball hones and piston and seal kits,only to have em leak air! After almost 20 years I don't have great hopes on these(after about four in a row that I tried to repair,I started recommending replacements!,plus a lot parts are becoming NLA for this system!) I know the replacement isn't cheap(about $125 at Cycle Parts Warehouse) but you would be surprised on how well it makes the old 250 stop! Just from my experience on these old master cylinders! OPT

 

Thanks for the help and info !

 

Ok so got the front shocks done, So how do I get the piston out of the master LOL ? read a lot on this and don't see any easy way.

 

You're really making me try to remember on this one! If master cylinder is still mounted on the handle bar,use some paper towels to soak up the brake fluid from the master cylinder.Remove the brake lever,then use a small pick to push the plunger in and with another L-shaped pick (cheap tools,you can get em anywhere) pull the seal out from the recess,then you can use needle nose pliers to pull the piston assembly out with spring and washer. IF the inside bore is corroded and rough, DON'T waste you time! Just get the replacement master cylinder! The kit has a new seal, o-ring and a cup seal at the end of the plunger. I still have the old cup seal compression tool that the plunger assembly slips into(which keeps the cup seal from damage)then you place up against master cylinder and push the newly assembled piston and seal and spring back into the master cylinder,then loosely place outer seal over piston,push piston in and seat new seal in place! If you don't have the compression tool(which I don't even think is available anymore!) you run the risk of damaging the cup seal when pushing the piston in! If mine I would throw the old master cylinder away! That's why I explained how to do the replacement,hoping it would scare you off! OPT

 

Thanks for the info, Just don't want to spend the money on a new one if I can help it. I have worked on rebuilding cars, motorcycles and ATV's for years so never can scare me off just looking for short cuts and advice.

thanks again

 

Happy Trails and may the Force be with you on the rebuild kit! OPT