Kawi2strokes.com Forum

I have a new kit and I pulled the master cylinder off of the bike. I pulled the boot out, and I can see the slotted washer at the base of the piston, but I don't know the trick to getting everything disassembled. I have a few different sets of circlip pliers that should come in handy, but from what I've heard this is a bit of a puzzle and I want to make sure I'm doing it right.

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1974 H1

Many times the circlip is coroded in. If yours isn't then pull the clip and everything will come out.

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Twist the throttle, tilt the horizon, and have a great time. What triples are all about...........

I had to use dentistry tools and lots of PB blaster to pry that sucker out. what a PITA! the inside of the cylinder was lal pitted from rust and whatever powdered brake fluid was left inside. a strip of emry tape rolled onto a bolt and stuck in a drill cured that up real nice.

Ah, I cleaned a lot of the crap out and I can finally see the circlip. This one's going to be a pain to get out...

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1974 H1

Kawasaki has offered a special tool for these master cylinder circlips for decades. They feature a triangular cut pin set, to clear both the bore and center plunger.

One thing that MIGHT help if you have standard circlip tools is, place the master with its lever end up in a vise, with padding, and, push the plunger down into its bore, then use the circlip tool. I've done it this way on a couple of tough master's.

Got it!

I grabbed a pick set at the hardware store. Then I took a 10mm deep socket and slipped it over the piston, then it it with a hammer a few times. This loosened everything up and broke the circlip free of its corrosion. From there I was able to use the picks to spin the circlip around and eventually grab it and lift it up. Worked great. Thanks everyone!

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1974 H1

I don't think I've done that in the past, but I'm sure going to try it next time.

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If it surges, that's normal, upshift.

I used scrap steel braced against the shelf above to compress the piston while I got in there with the picks.

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1974 H1

i like it .
what do they say about nessecity being the mother of something.
things you have to do in the garrage to get it done.
mark

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she will never be pretty but she is a fun ride.

73 KAWASAKI H1 (Sold).
82 YAMAHA RD350LC
2000 KAWI KDX200H
2001 Triumph TT600