Hey guys,
I'm trying to figure out how to rebuild a master cylinder. (The shop wanted like $170 to do it... I don't think it's
that much work...) So, here's what I'm trying to do. Tell me where I'm going wrong! I only have my Clymer manual to work off of, and this is all it says.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240022.jpg)
I have the MC cleaned out and my rebuild kit package open, so here's all the parts in what I believe is the order they go in according to the manual.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240001.jpg)
So I started by putting the little valved cap in the open end of the spring...
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240016.jpg)
...and then the valved end goes in first, correct?
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240017.jpg)
Next are these two little rubber caps. The left one is closed, the right has a nice hole.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240018.jpg)
All I can figure to do is stick them together and put them in the cylinder closed-end first.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240021.jpg)
Next is the plunger assembly, which I believe goes this way?
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240010.jpg)
the washer and the the ring go on the open end of the grey plunger, then the dust cap slips over and fits into the ridge on the plunger.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240012.jpg)
...and that leaves me with an extra piece.
![](http://i281.photobucket.com/albums/kk223/Chippy569/Motorcycle%20Rebuild/P6240013.jpg)
So I'm pretty sure I screwed up somewhere... any ideas?