Honda MSX125 Grom 2013-2018
5 Front brake master cylinder
Note:
Brake master cylinder rebuild kits containing the rubber boot, circlip, piston, cup, seal and spring are
available, and the rubber boot and circlip are also available separately. The master cylinder can be
overhauled while mounted on the handlebar - ignore the removal procedure and follow all Steps in the
overhaul procedure. If you prefer to remove the master cylinder to overhaul it ignore the Steps in the
overhaul procedure that have already been carried out.
Warning:
To prevent damage from spilled brake fluid, always cover paintwork when working on the braking
system, and have plenty of absorbent rag handy to catch and mop up any spilled fluid, and a suitable
container into which brake fluid can be tipped. Caliper overhaul must be done in a clean workspace to
avoid the possibility of dirt entering the system. Do not use petroleum-based solvents to clean brake
system components - use only clean DOT 4 brake fluid, a dedicated brake cleaner, or denatured
alcohol.
Removal
1 Remove the brake light switch (see Chapter 7 ).
2 Remove the brake lever (see Chapter 4 ).
3 Slacken the reservoir cover screws (see illustration) . Unscrew the brake hose banjo bolt and detach the
banjo union, noting its alignment (see illustration) . Seal the banjo union using a nut and bolt and the two
sealing washers, or a dedicated tool, or wrap plastic foodwrap around it (see illustrations 3.1b and c) .
Secure the hose in an upright position. New sealing washers must be fitted on reassembly.
5.3a Slacken the cover screws
5.3b Brake hose banjo bolt (arrowed)
4 Unscrew the master cylinder clamp bolts and remove the clamp, then lift the master cylinder away from
the handlebar (see illustration) .
5.4 Unscrew the bolts (arrowed) and
remove the master cylinder
5 Remove the reservoir cover, diaphragm plate and diaphragm and drain the fluid into a suitable container.
Wipe any remaining fluid out of the reservoir with a clean rag.
Overhaul
6 Remove the brake lever (see Chapter 4 ).
7 Undo the reservoir cover screws and remove the cover, diaphragm plate and diaphragm (see illustration
5.3a) . Suck the fluid out of the reservoir using a syringe or syphon tool and transfer to a suitable container,
or soak it up using absorbent rag or tissue and dispose of it. Wipe the residual fluid out of the reservoir.
8 Remove the rubber boot (see illustration) .
5.8 Ease the boot out
9 The piston assembly is secured by a circlip - release it using internal circlip pliers and draw out the piston
and spring (see illustrations) .
5.9a Release the circlip…
5.9b … and remove the piston and spring
10 Clean inside the master cylinder with clean brake fluid. If filtered and un-lubricated compressed air is
available blow it through the fluid passages.
11 Check the bore for surface defects and replace the master cylinder with a new one if any are evident.
12 All the internal components are supplied in the rebuild kit - use all of the new parts regardless of the
apparent condition of the old ones.
13 If not already in place fit the cup and seal onto the piston with their wider sides facing the inner end (see
illustration) . Fit the narrow end of the spring onto the inner end of the piston (see illustration) . Lubricate
the piston, cup and seal with new brake fluid, then slide the assembly into the master cylinder, spring first,
making sure the lips of the cup and seal do not turn inside out (see illustration) .
5.13a Make sure the cup (A) and seal (B)
are fitted as shown
5.13b Fit the spring onto the piston
5.13c Slide the spring and piston into the
bore
14 Push the piston in and fit the new circlip into the groove (see illustrations) . Release the piston and
check the circlip is correctly seated.
5.14a Push the piston beyond the
groove…
5.14b … then fit the new circlip into the
bore…
5.14c … and use a small screwdriver to
push it into the groove
15 Carefully push the wide end of the boot into the master cylinder and locate the narrow end in the groove
in the end of the piston (see illustrations) .
5.15a Fit the new rubber boot…
5.15b … making sure it locates as shown
16 Check the condition of the rubber diaphragm for the reservoir and replace with a new one if necessary.
17 Fit the brake lever (see Chapter 4 ), then fill the reservoir with DOT 4 brake fluid and bleed the system as
described in Section 11 . Test the brake before riding the bike.
Installation
18 Attach the master cylinder to the handlebar, aligning the clamp joint with the punch mark on the top of
the handlebar, then fit the clamp with the UP mark facing up (see illustration) . Tighten the upper bolt first,
then the lower, to 10 Nm - any gap should be at the lower joint of the clamp.
5.18 Align the gap in the clamp with the
punch mark (arrowed)
19 Connect the brake hose to the master cylinder using new sealing washers on each side of the banjo
union (see illustration 3.16) . Align the hose as noted on removal and tighten the banjo bolt to 34 Nm (see
illustration 5.3b) .
20 Install the brake light switch (see Chapter 7 ).
21 Install the brake lever (see Chapter 4 ).
22 Fill the reservoir with DOT 4 brake fluid and bleed the system as described in Section 11 .
23 Check that there are no fluid leaks and test the brake before riding the bike.
© 2019 Haynes Manuals, Inc. Contact us
