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Any brake rebuilders / experts on here?

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Hi,

Are there any members on here who rebuild brake units and/or are experts on units fitted to older (1995-2005) KTM /Dirt bikes?

I'm having a nightmare finding parts/rebuild kits for a Brembo master cylinder fitted to my scooter. (neither manufacturer or Brembo do parts / rebuild kits)

I have found out (suspect) the same model m/c was fitted on KTM and other dirt bikes.
But all suppliers of those rebuild kits say they cannot cross-check if it is the same master cylinder as my scooter and if their kit will fit.

If anyone is a brake expert or knows someone then I would be grateful if you could put me in touch to pick your/their brains.

Thx

Mark

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What year/model exactly is your "scooter"? I do a Google search for 2004 ('95-'05 is a huge range, gonna have to be a bit more specific than that) KTM Brembo master cylinder rebuild kits and get a little over 59,000 results, they're available roughly everywhere...

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8 hours ago, OLHILLBILLY said:

What year/model exactly is your "scooter"? I do a Google search for 2004 ('95-'05 is a huge range, gonna have to be a bit more specific than that) KTM Brembo master cylinder rebuild kits and get a little over 59,000 results, they're available roughly everywhere...

Yes they are available all over the place - the problem is that the parts in the kits are different to the parts in my master cylinder.

My scooter is a 2003 Yamaha Majesty 180cc EU model (YP180e) with rear disc brake. The build is the same as the 125cc model (YP125e/YP125r) and the Majesty range is the same as MBK Skyliner scooters. The master cylinder is a Brembo and the only marking which could be a model number is 'PS12' on the base. The bore is 12mm.

Type 'Brembo ps12 master cylinder' in Google and that brings up a whole load of fun - Brembo PS12 has variations of handlebar/foot master cylinders with internal/external reservoirs for mainly big bikes. There are rebuild kits for rear foot mounted versions of the PS12 mc but all the components are different.

All Balls do a clutch mc rebuild kit (click here) for a 2002 KTM SX65 the parts look almost identical to what is in my mc - without being able to cross check I have no idea if the bore size is the same and it will actually fit.

So to avoid ordering kits with unknown direct compatibility/different component diameters etc just to check them and find out they are different - then having to send it back and getting charged handling fees etc...

I thought if my model of mc was also fitted to dirt bikes I would ask on a forum if any members can confirm what make/model mc they have on their bikes. 

Thx.

Edited by Markie76

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This might be a stupid question, but have you tried going to a Yamaha dealer and asking at their parts counter?

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6 hours ago, Doc_d said:

This might be a stupid question, but have you tried going to a Yamaha dealer and asking at their parts counter?

Not at all, it's a very good question as you would expect the worlds second largest motorcycle manufacturer to provide an excellent service to their customers.

But the answer is yes and the best they (the 2 I tried) could do, is to advise I buy a whole new master cylinder!!!  

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51 minutes ago, Markie76 said:

Not at all, it's a very good question as you would expect the worlds second largest motorcycle manufacturer to provide an excellent service to their customers.

But the answer is yes and the best they (the 2 I tried) could do, is to advise I buy a whole new master cylinder!!!  

Yeah I figured you had already been down that road without any success.  Have you emailed Brembo?  It's a 50/50 shot but I find that some large companies will,go out of their way to be very helpful.  Then again the other 50% of companies suck.  If you decide to try that include all the relevant information such as the make, model and year of the scooter, the part number on the master cylinder and even a couple pictures.  Also tell them you've tried ordering the parts through Yamaha and they cannot provide them or the part number(s) needed.

Good Luck!

Doc

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I good used master cylinder can be bought for the price of a hard to find rebuild kit. Buy a common one and be done with it.

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On 03/07/2017 at 0:40 PM, Doc_d said:

Yeah I figured you had already been down that road without any success.  Have you emailed Brembo?  It's a 50/50 shot but I find that some large companies will,go out of their way to be very helpful.  Then again the other 50% of companies suck.  If you decide to try that include all the relevant information such as the make, model and year of the scooter, the part number on the master cylinder and even a couple pictures.  Also tell them you've tried ordering the parts through Yamaha and they cannot provide them or the part number(s) needed.

Good Luck!

Doc

Emailed Brembo today - wasn't easy as they don't have any sort of customer orientated contact us. 

The only 'contact us' I could find only has fixed topics, 3 for cars 3 for bikes and those only cover motorsports, replacing discs & pads or performance discs, callipers, pads.

 

I sent them my sob story and we'll see if they reply :(

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On 03/07/2017 at 5:07 PM, Russhole said:

I good used master cylinder can be bought for the price of a hard to find rebuild kit. Buy a common one and be done with it.

Well the used ones I've seen I wouldn't describe as 'good' unfortunately :cry:

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Do you have a bike wrecker nearby? its not new but may have some luck.

if you find a kit on ebay and the parts look the same can you message the seller and ask for measurements to cross reference? just a thort

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1 hour ago, vicxr400 said:

Do you have a bike wrecker nearby? its not new but may have some luck.

if you find a kit on ebay and the parts look the same can you message the seller and ask for measurements to cross reference? just a thort

There is a local breaker and he had a similar one but was only selling it as a complete instal - master cylinder & brake line & calliper.

I asked the ebay sellers but they won't help.

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hmmmm starting to sound like your running out of options.  can you post pix and measurements of the parts your lookin for? might help us identify what your looking for

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On 12/07/2017 at 6:23 PM, vicxr400 said:

hmmmm starting to sound like your running out of options.  can you post pix and measurements of the parts your lookin for? might help us identify what your looking for

Initially all I was looking for was a new circlip as my one broke on removal. But can't even get a circlip of that type on its own (16mm DIN984 with extra abutments).

Picture of parts in my m/c below.

The bore diameter is 12mm.

pistonbits.jpg

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ok so I know you mentioned ktm brembo  kits. I don't know if all the components would fit (depending on length)  this kit states that it is for a 12mm bore so the circlip  and the piston rubbers, dust boot and springs depending on length should fit. I know its not cheap but with little options cheap is not going to happen. my thoughts are get this kit and use what fits    ie. circlip, piston rubbers, and dust boot.  shy of buying a complete new master cylinder id say some thing like this is about your only option.

http://www.ebay.com.au/itm/KTM-FRONT-BRAKE-MASTER-CYLINDER-REBUILD-KIT-12-MM-2009-20012-54813008300-/282315838159?epid=737710465&hash=item41bb55d2cf:m:mydpP-Edb9qwRG5Jl39VWZA

I hope it helps and you get your brakes working again good luck and let us know how you went. feel free to ask more questions if need be il do my best to answer.

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Why can't you use a standard internal clip with a thin washer? just spin down (or get it done) the end of the piston to accommodate the extra thickness if need be. Seals should be available from any decent brake or seal specialist too. Just take in a sample.

 

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On 22/07/2017 at 0:59 AM, DEATH_INC. said:

Why can't you use a standard internal clip with a thin washer? just spin down (or get it done) the end of the piston to accommodate the extra thickness if need be. Seals should be available from any decent brake or seal specialist too. Just take in a sample.

 

1

I tried a plain circlip but it has minimal contact with the piston (see below) and I would prefer to avoid 'botches' where brakes are involved. I will give the washer idea a go but that might also be a bit of a mission to find a thin one in a suitable diameter. I don't have any metal working equipment or know anyone who does so that might be difficult. 

Here in the UK 'specialists' and local parts stores are a rarity, superseded by big names and chains who sell complete assemblies/parts backed up by powerful advertising that the correct option is to replace rather than repair. 

I searched for a 'decent brake or seal specialist' but no luck. All I found was performance brake suppliers for cars who are just re-sellers and installers.

54 minutes ago, vicxr400 said:

did you get your problem solved in the end????

No. I contacted Brembo but am still waiting for a reply. I won't hold my breath.

I'll leave it for now, maybe try and sell the bike and get a 'project' depending on how much I get.

Thanks.

plain_circlip.jpg

Edited by Markie76

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