1998 KLR 250 Front Master cylinder

Dom_V8 · L Plate Warrior Joined: 03 Dec 2009 Karma :

Hey,
I was wondering if I could use the master cylinder off a new YZ250 on my 1998 KLR 250. The YZ master cylinder has the same bore as the KLR (12.7mm or 1/2") so any issue regarding braking power etc isn't an issue.

I was wondering whether the brake lines would fit on the new master cylinder. Do I need to get new lines or anything to be able to use the YZ master cylinder with the standard KLR caliper??

The YZ master cylinder has a "banjo bolt thread pitch: 10 x 1.25mm" according to where I got it. I haven't been able to find any similar data stating the size of the "banjo bolt" for the klr, and I am only guessing at what the banjo bolt really is.

Thanks

smegballs · World Chat Champion Joined: 28 Oct 2007 Karma :

Shouldn't be an issue but I'd use the KLR bolt in the KLR caliper and the YZ bolt in the YZ m/c. The actual banjo fittings on the hose itself should be fine but you may need to make sure that you have ample copper washers as they can be a bit pissy when mating non-standard bits of kit.

I has a Aprilia RS125 m/c hooked up to the caliper of a Yam SR125, to date its the best setup I've ever ridden with.... Loads of feel yet would haul up rediculously quickly with only two fingers on the trigger. After a bit of fannying around with copper washers to make it seal it was fine.

I'd go for it and see how it turns out, is there any particular reason you arn't using the stock KLR m/c?

Dom_V8 · L Plate Warrior Joined: 03 Dec 2009 Karma :

Yeah its kinda missing the fluid window, the diaphragm and the resovoir cap...

I was looking at a couple of pictures on the net and the spot where the lines attatch on the YZ looked WAY smaller than that on the KLR.

Thanks for your help so far Smile

smegballs · World Chat Champion Joined: 28 Oct 2007 Karma :

Don't worry about missing the window.

A penny and expoxy resin will sort that out no probs... Thumbs Up

Top and cover off ebay?

Dom_V8 · L Plate Warrior Joined: 03 Dec 2009 Karma :

Yeah I thought about just replacing the stuff before and someone told me I could replace the fluid window really easily. But it just seemed too much trouble at the time and the YZ master cylinder was only $30AUD.

A new KLR master cylinder retailed at $300AUD!!!!!!

Now I'm thinking it might not be such a bad idea repairing it using your epoxy method Smile

!!! The only problem is it's my Dads bike and I don't think he will be too impressed with a DIY repair, especially since it's for his brakes.

Thanks again for all your help. I don't know how to leave good feedback for you though... Laughing