xj550 front master cylinder rebuild

I am going to rebuild my xj550 maxim front master cylinder. I am a reasonably able mechanic bbut have never done a rebuild like this. From looking at the part ( the body of the master cylinder) it is not obvious how to go about reving the old one and installing the new one. I have looked at some schematics on a coulpe of parts suppliers web sites but that did not offer any help. I am also new to this forum stuff. Anyone have any instructions on how to go about repair or knowledge of a website that might have some instructions? thanks

 

I believe it will be similar to the one on my 650.

Remove the brake light switch (there is a little catch on the switch body, push up into the hole under the switch with a small screwdriver to pop it loose).

Remove the mirror.

Remove the brake lever. There is a spring between the lever and the master cylinder body - if you ease it apart it might not fly too far.

Break the screws loose on the MC cover.

Remove MC from handlebar.

Drain fluid.

There is a rod that pokes through a rubber boot near the brake lever pivot. Pull the boot off. Don't worry about damaging it, there is a new one in the rebuild kit.

Underneath the boot you just removed is a circlip. Use a small snap ring plier to remove (or grind ends of needle nose pliers as described elsewhere by Rickomatic.).

The plunger with it's cups, the spring etc will now pull out of the master cylinder. Throw it all away - this is what is in the rebuild kit.

Clean MC body. Inspect bore for pitting etc.

Reassamble using new parts.

Put everything back together.

Fill with new DOT3 fluid.

Bleed the heck out of the front brake. Let sit overnight. Repeat bleeding.

 

You could also try looking up the cost of a BRAND NEW Master including Lever from:
mikesxs.com..
Approx $59 not free..(athough yr saving the cost of rebuild kit) but REAL easy... and seriously reduced chance of F'ups Shiny new too.