Non OEM Front Brake Master Cylinder

[drifter-paul]

I give up.

Tried everything reverse 'bleeding' , caliper up high to let the air rise and bleed, pumped fluid back up to the mater cylinder, pumped the caliper pistons out and re-inserted them, got lots of air out, then put the caliper lower, and flat to to the bar.

Now I'm trying to find the link for interchange-ability between VN versions. Can't get J parts or R1-R3 calipers (Ron Ayers/Partzilla microfiche), then the R4/R5 caliper numbers are different & the fork numbers are also different to earlier versions - implication being they won't cross-fit !

Anyone fitting alternative front caliper to the J series

I don't want to go thru the whole process of trying 2nd hand parts again.   

Thanks

P.S. Hanging out for a ride on the Drifter - with Covid19, not supposed to be going out except to buy groceries (the VStrom has luggage capacity so I do get out) , my sorrow goes out to you all , with the terrible death toll u r experiencing.

[greenbarn]

parts diagrams in general are bad that way....   not necessarily true to life.   They (manufacturers) use the same parts illustrations for multiple years/makes/models. 

[drifter-paul]

Got a '99 VN1500 (don't know if Classic or Nomad) master cylinder for $100 from a wrecker. Got it home to find the piston is 1/2" (12.7mm) and my old one is 13.8mm, so I can't use my new Drifter piston kit !!

Have cleaned the 2nd hand one, and blown it, now giving it some engine black, before testing it.

The interesting thing though, is that all the parts fiche for Ron Ayers/Partzilla for all models for multiple years from 1996 show the piston assembly as being the same shape as the one I took out of the Drifter. But the 2nd hand one uses a different spring /washer placement. Photo attached - trap for the unwary. Can anyone confirm the part number for the 1/2" piston with screw on spring in the photo - in case I need to get a new kit.

Thanks 

[Bucko]

Here's a used one for $10.50 https://www.ebay.com/itm/01-05-KAWASAKI-VULCAN-1500-VN1500R-DRIFTER-Front-Brake-Master-Cylinder/183775931814?hash=item2ac9e62da6:g:JlIAAOSw6tta-div

[drifter-paul]

Bought a cheap small master cylinder (also a short length of banjo'd hose) to isolate each component - including the new custom hose. Tested off the m/c, with bleed nipple as highest point. Primed the master, cracked the banjo at the caliper, pumped away and got lock/pedal.  Squeezing the lever again, got lock again.

SO far so good.

Swapped back to the Original master (with new piston kit) and repeating the process. Got a lock, but it wouldn't hold. Releasing and then applying the lever again, it went straight to the bar !!!

I figure the fluid is being compressed but then leaking back past the piston - worn bore.

Ah well, I don't mind buying the most expensive part now. Probably a Classic/Nomad VN unit new, and then rattle-can it black.

[Bucko]

"Bolt Bleeding" (unscrew the banjo bolts while under pressure to release air trapped on the bolt ends) works well but can be hard on the paint if you're not careful.

[drifter-paul]

Have done the brakes for the life of the m/c and for other m/cs. Not happy about it, my mate (also  experienced with cars) & I have been going nuts trying to figure out why it has been so recalcitrant . Will give it one more go with the pressure bleeder with his help.

[Bucko]

Lots of OEM used ones on eBay for cheap (may not be black though).  But are you sure you really need one.  These brakes (like all brakes) can be challenging to effectively bleed (i.e. get all the air out) at the best of times.

[drifter-paul]

Bucko/Chief,

Again a wealth of knowledge (I love this forum) - don't know why I thought the Drifter bars were oversize.

Following your advice, and checking more microfiche, it appears (Ron Ayers) that from Drifter 2001 the Classic part is substituted(as you say Bucko, different finish).

At the US price $345 plus shipping plus exchange rate plus GST, I will start looking for after market here - at least the range will be larger than I was expecting.

Thanks Guys

[chief]

ALL Vulcan 800,900, 1500, 1600 and 2000 have 1 inch. A couple of the 1700's had 1-1/4 (Voyager and Vaguero ). Most bikes have one inch, a few have 7/8 and fewer still have 1-1/4.

[Bucko]

Are the 2001 onwards Drifters, 3/4" ? The part is listed as fitting 1999/2000 for 800 & 1500 cc only.

They all have 1" bars.  The part numbers are different because M/Cs were black on the 99/00 and 'clear' on later models but are likely the same unit except for colour.

[drifter-paul]

Time for a new Master cylinder for my  '99 1500.

After replacing master piston kit, and a new hydraulic hose, I have bled, reverse syringe pumped, gravity (calipers/ bleed nipple at highest point) bled, pressure bled and can get it to work off the m/c. But it won't on the m/c !!!

Neither Ron Ayers or Partzilla  or Japan have the unit.

Who has had an alternative ? Harley ? The 1" handlebars restrict the choices available.

Are the 2001 onwards Drifters, 3/4" ? The part is listed as fitting 1999/2000 for 800 & 1500 cc only.

Thanks