Decided to Junk My 82 XJ1100

As the title states I have giving up on my 82 XJ1100J. I have owned it since August of Last year and successfully rode it for about 200 miles. Have never been able to get the rear brakes working properly so it has been a scary 200 miles of no brakes except one caliper in the front.
I have ordered enough parts to build 3 sets of rear brakes with no luck. New brake yesterday that were not correct. Tried bleeding them yesterday with the old pads to find out I can't get any pressure what so ever. Everything has been cleaned and new rebuild kits in everything, just to find out the last diaphragm I got and put on the master cylinder is leaking and tearing at the edge.
Thanks for letting me vent on here and now I guess another old Yamaha is going to be stripped as a parts bike, which is a shame since it has all new connectors and the engine is strong as hell.

Thanks for all the help, Mitch

 

Sad day.

 

It is. I'm just at my wits end with this thing. I hate to look outside and see it in the yard.
I can try to bench bleed the master cylinder and the first time i pump it up it builds pressure perfect, next try no pressure what so ever.
I've looked everywhere for an actual photo of the plunger assembly to make sure I have it back together correctly because the manual picture sucks for details.

 

The plunger in the master cylinder is easy.

Each of the rubber cups has a uniquely-sized hole, so they can each go in only one position on the plunger.

They go "lips facing in" for both of them.

It sounds like the bore of the master might be corroded; or the tiny hole in the bottom of the reservoir is plugged.

I wouldn't give up on a bike because I couldn't get the brakes bled. Yamaha brakes are a known PIA to bleed, we've all been there.

 

Blue Stang, why are you giving up? Where are you at? what have you done? There's probably board members near that can help out!

 

I've poured money into experimenting with no results what so ever. I've bought 2 M/C from xs's and rebuilt them with no help. I've rebuilt the caliper. Nothing seems to work on this thing.
I ordered a complete m/c just to get the diaphragm for the top and now it is cracking to.

Whats the best way to bleed these things without a mighty vac?

 

Top of the plunger is where I'm confused, what order does the gasket, washer and cap go in?

 

Bring it to me before you scrap it, I'll have it running and stopping in a few days. I am looking for another XJ11 if you are not too far from central NC.

 

I found that I have a problem in the plunger setup itself. I tried pumping fluid backward through the system and it goes good till it gets to the plunger and it refuses to let fluid back into the m/c. I can remove it and cover the bottom hole for the plunger with my finger and it squirts fluid back through the relief hole.

 

So you're giving up on the whole bike because of a lousy master cylinder problem? Don't give up.

I had similar issues with my intruder. No matter WHAT i would do, I would have brake loss at the front. Pump it up, it would stay rock hard as long as I didn't move. Go 4 ft and I would have no brakes.

solution--rotor was bent. Replaced rotor. Never had a problem since.

Dave F

 

You have the plunger rod adjusted too long. It is the rod that connects to the brake pedal. Loosen the nut and shorten it a few turns.

 

It's not even on the bike i have the whole brake system on my work bench hooked together. Can't get any pressure to build up, not sure if the plunger parts are all assembled in the correct order, and the plunger refuses to push back down after being pushed up with pulling it down. How much movement up and down should the plunger have inside the m/c?

 

The plunger should move free without any binding. You might need to polish the bore with a scotch-brite pad. I wrap some around a wood dowel and turn it in the bore. Clean the plunger also.
after cleaning put the spring in(lube all parts with clean brake fluid), solid plunger cup with taper facing in. assemble the plunger with the bottom seal(taper facing to MC). the thin washer goes on top of the plunger . push the plunger in against the cup and spring. secure with washer and snapring. You should be able to push it in and the spring should push it back and stop at the snapring.

 

Thanks, I tried the scotch-brite pad, everything looks good and clean and smooth, lubricated everything put it back together and it still will not push the plunger down freely. Tried 3 plungers and 2 m/c with the same results from all.

 

Just so everyone knows what he is talking about. It's not the master cylinder on the handle bars. These bikes have a master cylinder behind the engine since this bike has rear disc brake. The rear brake lever actuated the rear master cylinder and one of the front calipers. This system is really hard to get the air out and bleed.i use a hand held vacuum gun to pull fluid through but more important you have to bleed the master cylinder just like a car one in a vise and a tube running back into the reservoir. Pump it untill the air is gone. Then it should work. If not the cylinder is not put together right or there are wrong parts inside. You never know what the PO .was up to.

MN

 

The original m/c is gone I'm working with 2 xs m/c's just trying to get the rear brakes to work with no luck at all.

 

For all your trouble and money what is another $30? For a mighty vac?

 

Not sure what the XS1100 Master cylinder looks like but if it looks the same and bolts up it should work. Bench bleed it first and see if you can borrow a hand vacuum pump to pull the fluid through both calipers. If you need a rear master cylinder I'm sure we could come up with one. But try to bench bleed it first and see if you can get a solid fluid flow through it.

MN

 

The XJ and XS11 rear master cylinders are different. The XS cylinder will bolt up but since the XJ11 has linked front and rear brakes the XJ has a larger bore and a intregrated proportioning valve. If you de-link the brakes then you can use the XS MC.

 

That must be part of the problem. If the bore is too small there is not enough volume of fluid to work the brakes.
He will need to find the proper part to make it work.

MN

 

The front brake was already unhooked from it when I bought it and it had the xs11 m/c already on it. It acts like the plunger is getting airlocked and can't release itself. Only way it will without pulling it down is to pump fluid from the caliper bleed screw back through it then it pops back down.
I have it on the bench tonight with plunger clamped up in it, full of fluid, and the caliper with the bleed screw open below it hoping it will gravity bleed the air out to help get going.

 

Not a good idea... been there, done that.... build a plan of attack.

Try the correct part...

Find a friend or local forum member with a Mighty Vac.

We'll get you through this!

 

The plunger should come back down from the internal spring pressure. It is pointless to try to bleed it until you get it to work right. That MC needs to come apart to inspect the bore and plunger. Have you got a rebuild kit for it?

 

The front brake was already unhooked from it when I bought it and it had the xs11 m/c already on it.

Your best bet is to find the right parts to make this thing work properly. Sounds like you have been getting beat up trying to make something work that is not right.

Someone here has to have what you need or I would bet someone knows where you can get the right stuff. Did you check with Len xj4ever? He should have all the right parts to get that going again.

 

Yes it just had a new rebuilt kit put in it and everything was cleaned and checked. It just refuses to push the plunger back out.

 

Unfortunately my cash for this bike has run out, i either have to fix with what I have already, or decide the next step for it.

 

Better to park it and come back when you have the money to do it, or find a buyer that has the means to get it back on the road again.
In any case good luck.

 

Did you get the kit for the XS11 or the XJ11? The bore sizes are different, if you have a XJ kit and are trying to put in the XS MC that will explain your problem.

 

The kit I have is for an XS. its the kit pictured here
http://www.ebay.com/itm/XS1100-REAR-MAS ... ba&vxp=mtr

 

Where are you located Blue Stang? I think everyone here will agree that it's not worth junking a bike like that because of an issue with the brakes. Best to find a local who can help, or who has the time and money to keep the bike on the road. Best of luck!

 

I'm located in Southwest Va

 

Post some pics of your bike. I am near Raleigh NC and wpuld come pick it up if we agree on a price and you want to sell.

 

i sure hope you dont give up man, i'd say park it till oyu have the funds to buy another correct m/c and rebuild it. good luck man, have faith.