Intsalling Nissen Radial Master Cylinder

[ride57]

Again, another chapter of my 748 mainteneance/modification saga.

I got a Nissen radial master cylinder (fits Honda CBR1000RR) also the handle, handle bolt and banjo bolt.

Below is a pic of the stack cyl. I took off the fork mount, and the cylinder. There is a roll pin that needs to come out. I was thinking about drilling a locating hole in the new cylinder, but it did not look thick enough, so I did not risk it and just took the locatiing pin out.

Stock cyl

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug050.jpg

New cyl

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug049.jpg

Locating pin to take out

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug054.jpg

Initial fit of new cylinder. Note where throttle cable must be routed.

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug055.jpg

initial fit seems to be ok. You can see the nub where the wires come out. This needed to be removed to provide final clearance.

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug057.jpg

However, when I put on the fork piece, you can see that there is not quite enough room as the cut on the bar for the bolt will not line up.

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug064.jpg

I had to take off the on/off /starter switch and modify a bit. The wires originally came out of the side of the switch on the bottom and it had a little nub for a zip tie. , I dremeled the nub off, and then cut (carefully) into the switch so the wires now come out of a existing hole on the bottom. I also cut into the switch a little to provide room for where the banjo bolt is on the new cylinder.

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug059.jpg

This shows, how I notched the switch housing for the cylinder

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug066.jpg

Now it fits the clip on!

http://i38.photobucket.com/albums/e109/88sporty/ducati/doug068.jpg

I may need to do some creative mounting of the resevoir to clear the fairing. With 2 resevoirs and mounting brackets, I dont think that will be a issue. What I think I may have a problem is with the original brake lines aligning up without having to twist the banjo to fit. I may need to go to dual lines. That will have to wait untill I start putting things back together again.

[sport1000]

Always impressive!

[Scottsst]

you are a true inspiration to any and all ducati owner's that works on his/her own bike

[Bong]

Thanks for posting detailed pics of your progress, going to be fun to get that 748 on the road with all the modifications!

[ride57]

Well, I got the brake line bolted up and soldered connectors for the brake light switch. I still have to wait to get the fairing on to do the final positioning of the master cylinder and see what resevoir will work best.

http://i38.photobucket.com/albums/e109/88sporty/ducati/vegas008.jpg


ETA: Also have to silicone the wire outlet of the switch assy.

[ride57]

well, back at it fitting today, the first three show the stock Honda resevoir with unmodified bracket just barely hitting the fairing. It looks like I could just make the rubber washer thinner and maybe bend the bracket down it will miss the fairing. Also I think if I put the Ducati resevoir on it might miss the fairing also.


http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics002.jpg

http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics003.jpg

http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics004.jpg


But.......... the next 2 pics show the brake lever hitting the instrument cluster. Its about 1/4 inch from the stop (second pic) I can't move the lever down any more as I have already trimmed as much as I can on the start/stop/starter switch assy.

I could try to grind a little on the brake lever along with trimming a bit of the plastic off of the cluster (not the foam).

Or I could remove and relocate the switch assy.

Decisions, decisions.

http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics005.jpg

http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics006.jpg

The last, I'm trying to show the brake lever where it hits the instrument cluster.


http://i38.photobucket.com/albums/e109/88sporty/ducati/Alishaspics007.jpg

[Dave R]

Using radial pumps on a 748/9*6/998 series always creates an issue with clearance. Non adjustable stops make it even harder ! I believe you may be able to solve it by switching to some helibars. They will flatten and bring the bars back a bit giving you more comfort and clearance.. : ) Search and you can find some used out there. the FBF risers set up wouldn't improve things IMPO, try the heli's