Front brake lever not connected to master cylinder '82 XJ650

Hey all,

I recently got a 1982 Yamaha XJ650 Maxim for free. It is in non running condition, but I have now unseized the engine, cleaned the tank, carbs, and double checked all electric. She fires up with some gasoline sprayed into the airbox (currently rebuilding the petcock, so the tank isn't on.)

I went to work on the front brake. The lever had no pressure, so I assumed no brake fluid. I open up the master cylinder and there is indeed fluid, albeit dirty, but it should still cause some pressure. Turns out, the lever isn't connected to the master cylinder at all.

Is there any way to fix this without spending too much money? I am homeless and money is tight. Just trying to get this ridable so I can make some money. I have a full set of tools, and I am pretty capable, just never worked on motorcycles brakes before.

 

Here is another picture with the handle taken off. I am not sure how it is supposed to connect, but I presume it would connect on the little rubber boot/metal piece that's in the housing, correct?

 

The 6mm adjustable "bolt" pushes on the back of the piston. If it's not then the piston isn't returning, meaning there is likely some corrosion between the piston and the cylinder.
Remove the circlip, tap the piston in and out with some lube in there and fit a service kit from @chacal (click on the cyclic icon at the top right of this page).

 

You will need to do a full clean on the front MC for sure. As @Minimutly stated, the plunger is stuck at the "in" position and not returning to the "at rest" position or the outer most that the internal spring should be pushing the plunger out. I would guess if you open the fluid holder cap, it is either brown or completely dry inside the brake fluid resistor. All part of getting a nice project back on the road.

 

Thanks for the reply. I will dig into it a little more. I would love to get a service kit but I don't have an address to ship to. Hopefully I can figure it out without the service kit.

 

Yea, it was definitely brown inside the master cylinder reservoir. I will do a good cleaning on it and see if I can get the piston moving freely again. Thanks for the help.

 

You almost definitely will need a service kit, need to work out how to get one...

 

I got the cylinder all taken apart. Definitely dealing with some corrosion. The rubber boot around the piston is somewhat dry and cracked. The other rubber pieces are fine. Also found some corrosion inside the cylinder, and on the piston. I may see if I can find a service kit on Amazon and take my chances. I appreciate the help.

 

Make sure you keep all corrosive cleaners away from the rubber parts if you plan on using them again. The metal area's that have built up need to be cleaned and then coated with fresh brake fluid before assembly. Upper right hand coroner of any page will take you to LEN and his great parts. He will get you the right parts for the job the first time.