Master Cylinder swap possibility - Kawasaki Vulcan 750 Forum : Kawasaki VN750 Forums
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post #1 of 14 (permalink) Old 09-29-2015, 12:26 PM Thread Starter
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Master Cylinder swap possibility

I'm trying to resolve a few front brake related line items on my '86:
Broken switch for brake lights
Torn up protective rubber boot for brake hose to master cylinder
Sight glass is in rough shape (and actually flexes to the touch)
Broken brake lever

Obviously the simplest way to solve most/all of these at once is to replace the whole assembly in one shot. I've got a bid in on a round master assembly pulled from a '93 that would fix it here.

Another possibility occurred to me last night. I purchased a replacement master cylinder for my '83 Silverwing a couple of years ago that has never been used. It's got a 14mm bore and is set up for 10x1.25mm pitch banjo bolts and mirror mounts with a 7/8" bar. Does anybody know if these measurements would work on the VN750? I tried a search but couldn't find the bore diameter posted previously.
Here's a link to a current auction for the type of master cylinder I'm describing:
New Front Brake Master Cylinder Lever EX250 EX500 KLR600 KLR650 Kawasaki KLR | eBay

Thanks!

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #2 of 14 (permalink) Old 09-29-2015, 12:30 PM
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If the MC was used for duel discs, I see no reason why you couldn't use it, other than not having matching levers.

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post #3 of 14 (permalink) Old 09-29-2015, 12:34 PM Thread Starter
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Thanks, and yes - it was purchased for a dual disc bike. I'll probably end up finding a black clutch lever later to match it.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #4 of 14 (permalink) Old 09-29-2015, 01:48 PM
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I used the master from my goldwing on my vn750 and worked great

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post #5 of 14 (permalink) Old 09-29-2015, 02:11 PM Thread Starter
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Thanks! What started as a rather long list of things to order for the 750 has become quite a bit cheaper.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.
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post #6 of 14 (permalink) Old 10-29-2015, 10:38 AM Thread Starter
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For what it's worth, I ended up picking up a different master cylinder to use, as the one I pulled from the Silverwing acted a little funky after sitting for several years (no fluid in it, though). I'll troubleshoot it another day.

This one is working great and the dark master cylinder/polished lever are a closer fit to the stock colors on the VN750.


For $50 shipped I'm very pleased with it. That includes the master, lever, and switch. The only major change is that the brake line comes in from the left rather than the back of the master, but I had no trouble at all getting the stock line to fit in that location. I'll try to post some pictures of it mounted on the bike later.

Here's a link to the eBay seller's auctions for master cylinders that should work well.

1986 VN750 27k miles
1999 EN500 32k
1983 GL650i in pieces. Someday it will ride again.

Last edited by calebj; 10-29-2015 at 10:42 AM.
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post #7 of 14 (permalink) Old 10-29-2015, 01:14 PM
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Thank you for the link

ONE RATS ASS GIVEN PER POST
Support your local FREEBIRDS MC
1986/5 Vn700/750 Frankenfook cross eyed bitch "Mellisa Fayhe"
I am a BIKER and i'm proud.FREEBIRDS MC CENTRAL NY

lowered with progessive 412 10" shocks
rejetted for K/N Pods part#rc 2340
sportster seat

'I didn't lose my mind.i gave it away

BRING BACK WOLFIE."Peace and Carrots"RIP
"And I'm free...as a bird"John Lennon Free as a Bird
"I only carry when I have my pants on"Joe Robinson RIP aka Old Dog
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post #8 of 14 (permalink) Old 11-04-2015, 06:55 PM
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Almost any front Japanese master cylinder made for 7/8" bars will work, if you have all the parts and lever. I don't know if there is any real difference between master cylinders for single/dual front discs. They look the same, including internal parts. I am using a single front disc (been using it for over 60,000 miles) with the stock master cylinder. Works fine. It is possible that some master cylinders might not provide enough leverage for dual discs.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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post #9 of 14 (permalink) Old 11-04-2015, 08:34 PM Thread Starter
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Jerry, it's a function of bore diameter versus caliper piston surface area. I'm not sure what the 750 uses stock, but 14mm is common for dual disk systems. As I understand it, a master cylinder that's too narrow will give an easier lever but may hit the grip before moving enough fluid to lock the brakes. On the opposite end, going too big will be harder to squeeze and may create a very wooden on/off lever feel.
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post #10 of 14 (permalink) Old 11-04-2015, 10:20 PM
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There are a lot of variables. A lot of different bikes have a different front brake feel, regardless of whether they are single or dual disc. I noticed that the 2001 1500 Drifter, 1500 Classic, and 1500 Nomad all use different master cylinders. The Nomad has dual discs, the Drifter and Classic have single discs. No way to know whether the differences are cosmetic only, or whether there are also functional differences. I found the Vulcan 750 to have a very grabby, hard to modulate front brake. I removed the right front rotor and caliper, and am just using the left one. Brake feel improved dramatically (for me) It takes a little more effort, but it is still easy enough to lock the front wheel. And in 60,000 miles I have noticed no unusual parts wear, or loss of performance when hot. That is using the stock master cylinder. My 2013 Royal Enfield, which has a single front disc, completely stock, has about half the braking power of my single disc Vulcan, and it is almost impossible to lock up the front wheel. Also notice bike weight. The lighter Vulcan 750 came with 2 front discs, yet the much heavier 1500 Drifter and Classic only came with a single disc. They are from a different era. The Drifter and Classic were designed mostly for looks (Indian and Harley copies) while the 750 came from a time when manufacturers were trying to put as many features as possible on their bikes.

I am a motorcyclist, NOT a biker.


1997 Vulcan 750, purchased about a week ago
2006 Sportster 1200 Low
2013 Royal Enfield Bullet 500, converted to carb
2001 Yamaha XT225, heavily modified
2004 Honda Rebel 250
1979 Vespa P200E
2002 Vulcan 750 parts bike
1994 Yamaha XT225 parts bike
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