How to swap radial master cylinder

wb_map3 · Nov 27, 2009

Ok so I just did this write up but in the process I got logged off so I hit post and it made me log back in and everything got deleted so this write up will not be as in depth but you can get the point

On a scale of 1-10 (1 being the easiest and 10 being the hardest) I rate this a 2. Any one that can turn a wrench can do this mod.

with that being said this is my first how to so please do not bash if I was not perfect in my descriptions

The 03-06 m/c comes with the resevior built in, it is a big ugly box so this mod is not only benneficial to better braking power but also the overal looks of the bike.

I used a m/c from a 07-08 m/c, not really sure because they both look alike. It cost me 60 bux shipped but there was members selling them for as low as 20 bux shipped I was just in a hurry to get it and he was the fastest to reply several times so I went with him.

That being said lets get started,
it does not matter what order you do step 1 and 2 but this is the way I did them

1)Disconect the 2 bolts from the m/c, there is only 2 and they hold the m/c to the clip on. On some bikes it is an 8mm and some bikes it is an allen head. take these off and then pull the m/c from the clip on.

2)Now you need to disconect the banjo bolt from the m/c, this is the bolt that holds the 2 brake lines on to the m/c

3)Now that you have all that done take your new m/c and connect the brake lines to it, I found it is easier to connect the brake lines to your m/c before installing it on the clip on, they are a pain in the ass to get to the propper angle.

4)When you get those connected then connect the m/c to the clip on the same as your other one was, it is just 2 bolts. Snug the bolts down but not all the way tight.

5)Turn your wheel to the left as far as it goes, see if anything hits, if the resevior hits then push the m/c up or down (toward the sky or ground) until it no longer hits. Tighten down the 2 bolts again.

6)Recheck that nothing hits, if it is all still good then add fluid and you are done.

7)You probably need to bleed the m/c also but I have my bike apart for other mods so I have not gotten to this part yet.

If anyone has any insight on this mod please post your knowledge, the more knowledge the better for people reading it and the easier it is for people to complete mods, if I left anything out then post it and if anyone has any questions then post them an I or another member of the site will answer them for you.

travr6 · Nov 27, 2009

Looks like a decent write up. Pictures would be helpful though

wb_map3 · Nov 28, 2009

It is all so simple there is nothing to take pictures of.

wb_map3 · Dec 3, 2009

ok so a little more info on this, the 07+ master has a brake line mount underneath the master and not on the side like the 03-06 master does, that being said, if you are running the 03-04 forks you WILL HAVE TO BUY AFTERMARKET CLIP ONS, if you have the 05-06 yours mite work I have no clue if your clip on length is longer than the 03-04 length, if your length is not long enough for the mod on the 05-06, then it is a direct replacement with the 07+ clip ons, I do not know any of the lengths for the clip ons but other members who did the mod had 05-06 forks and just used the 07+ clip on because they got it all as a packaged deal, no 1 has tried it on the 03-06 clip ons except me and I found that the 03 length is to short, that being said I was going to get an 07 clip on until I found this,
http://www.woodcraft-cfm.com/clipon-chart.htm
as you can see the diameter is not the same for 03-04 so you will need to use an aftermarket clip on that is a tad longer.

scrappy600 · Dec 3, 2009

wb_map3 said:
ok so a little more info on this, the 07+ master has a brake line mount underneath the master and not on the side like the 03-06 master does, that being said, if you are running the 03-04 forks you WILL HAVE TO BUY AFTERMARKET CLIP ONS, if you have the 05-06 yours mite work I have no clue if your clip on length is longer than the 03-04 length, if your length is not long enough for the mod on the 05-06, then it is a direct replacement with the 07+ clip ons, I do not know any of the lengths for the clip ons but other members who did the mod had 05-06 forks and just used the 07+ clip on because they got it all as a packaged deal, no 1 has tried it on the 03-06 clip ons except me and I found that the 03 length is to short, that being said I was going to get an 07 clip on until I found this,
http://www.woodcraft-cfm.com/clipon-chart.htm
as you can see the diameter is not the same for 03-04 so you will need to use an aftermarket clip on that is a tad longer.

Don't have a clue what you're trying to say here, is it purely that the 03-06 side mounting reservoir causes problems as the lines are not long enough when you try attach them to the bottom mount of the radial master cylinder? Or what? I don't understand why you're saying that you need new clip ons. Can you explain it a bit better?

wb_map3 · Dec 3, 2009

scrappy...

03-04 forks use a 45mm clip on
05-06 forks use a 48mm clip on
07-08 forks use a 48mm clip on
09 forks use a 48mm clip on
I am not sure if the lengths of the actual bar are different but you can not use a 05+ clip on with an 03-04 fork. I assume that the length of the bars is different also.
The 03-06 master has threads on the side so the banjo bolt does not get in the way of anything else, on the 07+ it is on the bottom, it sticks out a bit pushing the throttle housing over and pushing the throttle tube off of the end of the bar by about an inch. So you need a clip on that is longer than the oem 03-04 clip on. I do not know the length of the 05-06 clip on so I can not give insight to if 05-06 owners have to use a different one but I know from asking other members that the 07+ clip on will work fine, the problem is it uses a 48mm and that will not fit an 03-04. make sense or are you still not getting it?

scrappy600 · Dec 3, 2009

wb_map3 said:
scrappy...

03-04 forks use a 45mm clip on
05-06 forks use a 48mm clip on
07-08 forks use a 48mm clip on
09 forks use a 48mm clip on
I am not sure if the lengths of the actual bar are different but you can not use a 05+ clip on with an 03-04 fork. I assume that the length of the bars is different also.
The 03-06 master has threads on the side so the banjo bolt does not get in the way of anything else, on the 07+ it is on the bottom, it sticks out a bit pushing the throttle housing over and pushing the throttle tube off of the end of the bar by about an inch. So you need a clip on that is longer than the oem 03-04 clip on. I do not know the length of the 05-06 clip on so I can not give insight to if 05-06 owners have to use a different one but I know from asking other members that the 07+ clip on will work fine, the problem is it uses a 48mm and that will not fit an 03-04. make sense or are you still not getting it?

i think i get you now, basically your saying that theres 2 issues with putting a radial on an 03-04, one definite issue, which is that the 03-04 clip on fits the 45mm fork and isnt long enough to accept the m/c when mounted. the 05 onwards use a clip on designed to fit over the upside down fork tubes (being wider) but the other issue which youre not sure is definite is that you dont know if the 05-06 clip on is long enough to allow for the m/c being wider due to the banjo at the bottom.
I'v ordered these below from ebay for mine

http://cgi.ebay.com/ws/eBayISAPI.dll?ViewItem&item=110369528569&ssPageName=STRK:MEWNX:IT

Mainly so i can keep my braided lines but im wondering if its a fix for what your saying happens with the 03-04 clip ons?

wb_map3 · Dec 3, 2009

honestly it will not make a difference and possibly make it worse, let me clear up what I am saying, 03-04 forks will only take 03-04 clip ons, 05-06 forks will take 05+ clip ons so you can just buy the complete 07+ clip on instead of just the master cylinder. the master cylinder will bolt to any clip on, they all use a 7/8 bar. The issue is not how wide it is but how long it is.
Here is a picture of another members 05 with the 07 clip on, it works fine, what I am saying is this, te part that the blue arrow is pointing to pushes you over a tad where as the 03-06 master has that on the side so it does not push you over a tad.

scrappy600 · Dec 3, 2009

i get you now, thanks for the pic thats all i needed as i have 1000rr m/c but its in my dads house so i couldnt check to see what you meant. hmmm..... a hunting i go for a 07 clip on!!!

scrappy600 · Dec 3, 2009

actually do you reckon just swappin out the kill switch for the thinner 07 version might cure all the woes? not sure what size one was on the 05/06 but the thinner 07 version might just free up enough space and save having to change the clip on. (just realised you'd need the throttle too - Doh!!)

wb_map3 · Dec 4, 2009

yea I do not think it is any thinner because you need the throttle housing too and the throttle housing and the killswitch together are probably the same size as the combined 1 on the 03-06 the only difference is that it is 2 pieces instead of 1. What year RR do you have?

wb_map3 · Dec 4, 2009

just measured my clip on, it is 7 and 1/4 of space that is usable then there is that part of the clip on that is raised up and can not be used, that part is 1 and 1/4 making the total length 8 and 1/2 inches long.

Azn-Sensation · Dec 4, 2009

Hey whats up wb map3, Im actually in the process of switching out my master and throttle tubes for a hrc setup and brembo rcs on my 06. Ive got a kill swtich from an 07/08 600rr that I'll be using, was it plug and play for you or did you have to move any pins around in the plug?

wb_map3 · Dec 4, 2009

That is actually a pik of another members bike, I am using the 03-06 kill switch and throttle housing with my hrc tube and 07 master cylinder. I decided not to use the 07 kill switch because from all my research on here i is NOT plug and play, you HAVE to move some pins from what I have read. I did a lot of research on the throttle housing and kill switch stuff before I did my hrc tube mod, I got the bike taken apart to do that mod and decided to do the master cylinder mod at the same time, then realised I could use new throttle cables and a new clutch cable so I am doing it all as we speak. I am almost done I am just waiting on my throttle cabbles to come in the mail and the pair block offs to arrive. then I will be good to go baby!!!

Azn-Sensation · Dec 5, 2009

Oh ok thanks! Are the throttle cables your using the stock oem ones or HRC ones?

wb_map3 · Dec 6, 2009

I went and got new oem ones, my old oem ones fit but I figured im in there why not replace them, I was going to get the hrc cables but they would of taken longer to get here and I wanted the bike together, so much for that idea lol.

scrappy600 · Feb 9, 2010

just to confirm that the 1000rr master cylinder WILL fit an 05/06 clip on and an 03/04 clip on, they are both the same length clip on. It all gets a bit tight and busy on there but it definitelly WILL fit. For anyone who thinks yeah but itll push the throttle housing down to the end weight, its not possible because there's a nipple inside the housing that locates to a hole in the clip on securing it.

wb_map3 · Mar 12, 2010

^^ takes 2 seconds to drill a new hole but the 03 and 06 are not the same length, besides why not just upgrade to aftermarket clip ons?

scrappy600 · Mar 12, 2010

because i dont need them at all, and also most threads ive read have had some sort of issue with clearance with the new after market clip ons. i only wanted to show people that it will fit on the oem clip ons at least then they know they dont have to go buying new aftermarket clip ons

Tim600RR · Mar 21, 2010

what year 1000rr m/c you use Scrappy? Im in the market for a new m/c on my 03.

scrappy600 · May 28, 2010

Tim600RR said:
what year 1000rr m/c you use Scrappy? Im in the market for a new m/c on my 03.

sorry for the delay replying to you ive only just checked the thread, its a 06/07 1000rr master. check out my build thread for a few tips on fitting the master cylinder, its not difficlut but its not quite 100% plug and play just needs a tweak here and there when fitting.

tripage · Jun 12, 2010

If you get an 07,1000rr,rc51 kill switch it will give you some more room on the clip-on. Also split your throttle cables "one on top of the brake lever and one on the bottom" Makes it look better and you don't have cables in the way.. T

SuperBrute · Jul 29, 2010

so if i'm understanding all this correctly, i can take a mc from an 07 cbr 600rr and it will be a direct fit to my 05 cbr600rr? or does it only work with the mc from a 1000rr?

thanks for clearing up my confusion

qs85ga · Aug 21, 2010

to make it fit .. pretty sure ur going to do like mine ... M/c .. kill switch .. throttle .. and 07+ lines .. but i think ur running braided lines .. my 03 line wouldnt clear the brake switch so .. tore it off and went w/ the newer 1's

good luck w/ it and ive got a wiring diagram i sketched for the kill switch wires

qs85ga · Aug 21, 2010

Soooo it worked !

had to use the 08 lines to make it fit though. Trimmed the excess metal mounts and reused the 03 "brackets " to mount .. works perfectly. Used the 08 switch and throttle .. fit on the 03's 45mm bars perfectly .. only clearance issue is full left turn .. i can make it to lock .. but its shy a few millimeters .. might be able to clear it up when my pazzo style levers are on.

wiring the kill switch was pretty straight forward .. will prolly post a diagram but just referenced colors from each years service manuals. Wasnt able to pull the pins from the 03 connector and the 08 pins didnt wanna fit ... so cut .. soldered .. and heat shrunk all the wires. works perfectly

took forever running the new throttle lines and getting that all set up .. also installed some diy v-stacks, added a new pc3, and cleaned up all the wires for the turn signals ect, installed some d3 grips, and finally took some pix of the torched ti exhaust.

Runs incredibly .. stops .. well .. it stops but just put new HH pads and wanna wear em in slow so .. havent nailed it or anything .. only have about .3 miles on it so far ... gunna take it out later tonight if it doesnt t-storm. Used the rbf600 fluid. Just waiting on my HRC res sock .. and its pretty much done ..

refer to http://www.600rr.net/vb/showthread.php?t=189995 if u wanna see all the rest

slim8 · Oct 12, 2010

just got my 07 1000 mc in and i dont think the 600rr brake lever will work, do i need to get the 1000rr lever?

scrappy600 · Oct 12, 2010

yes, definitely.

tripage · Oct 12, 2010

Have a complete setup here for someone wanting to do this.
http://www.600rr.net/vb/showthread.php?t=208703

boon03 · Nov 7, 2010

Can you post that wiring diagram? Im going to be wiring up an 07 kill switch to my 03 hopefully this week. Thanks!

miakae · Aug 22, 2012

I know this is an old thread but I'm hoping I can get some insight. I upgraded to an '07 front MC for my '05 and the banjo fittings (aftermarket ss lines) on the MC side are 90 degree long-throat which I believe will hit the ram air cover (don't know for sure as my fairings are still on their way). What banjo fittings did you all use to prevent anything from hitting? (2) 20 degree bend banjo fittings or (2) straight banjo fittings, etc?

Workinboy · Dec 24, 2012

I did this mod a couple months ago and it was a straight swap. I picked up a M/C off an 07 or 08 I believe with Galfer SS lines and had no problems.

PM me if you have questions and I'll send pics and that kind of thing.

How to swap radial master cylinder

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