CX500 GL500 650 Global

As with a lot of comments on Chopper Charles site, I'm sure I have read about somebody having my problem. However, since I can't get there from here, here it goes.

Today, my first run on the CX since it's complete rebuild, I discovered a bit of a problem. When starting out, everything was fine. Brakes, lights, signals, all checked out. I was thinking "she's ready for the safety check". Boy, did it feel good to get back on the road with my long lost friend.

However, after a couple times around the block, my front brake began to get more and more tight. By the time I returned to home, I could barely push the bike, as the front brake was wanting to lock up.

What I did:
I un-did the bleed screw at the wheel cylinders (it's a duel cylinder) which released the pressure acting on the brake cylinders, and the front wheel once again would spin normally. I deduced from this that the wheel 'duel brake cylinders' are moving properly - binding the disk while brake is engaged, and releasing when the pressure is removed.

What I'm wondering:
I believe the problem is in the master cylinder - it is not allowing the brake to release. Has anybody else experienced this? Does anybody have a solution? Is it possible I have reversed the order of the new M/C kit parts?

Notes: 1982 CX500 Custom with single disc in front - with duel cylinders.
'real honda' (not after market) Brake kits installed both at master cylinder and at disk.

When you went through the master cylinder did you look to see if you could see both holes in the MC. The one sucks the fluid in and the other relieves the pressure. Been there broke that. Many on choppercharles have suggested blowing the hole out with compressed air. Whatever you do don't drill it out. or if you do you will need a really really fine drill for like jewelery or something. I used one that was slightly to big and the brakes worked and everything but it let to much fluid relive itself. So until the piston past the second hole it shot the fluid back into the MC.

Thanks for the reply, yes, I did check that both holes were visible, and open. My fear, is the kit came with the piston, and a cup style o-ring thing. I fear I have installed this one onto the piston incorrectly (backwards) - but would like to confirm if anybody else has made this error - with the same results I got.

CXSarnia

I haven't heard about anybody getting the same results. If you really want to know you have the MC and all there that is keeping you from turning it around is a c clip.

Blindstitch2002 wrote:When you went through the master cylinder did you look to see if you could see both holes in the MC. The one sucks the fluid in and the other relieves the pressure. Been there broke that. Many on choppercharles have suggested blowing the hole out with compressed air. Whatever you do don't drill it out. or if you do you will need a really really fine drill for like jewelery or something. I used one that was slightly to big and the brakes worked and everything but it let to much fluid relive itself. So until the piston past the second hole it shot the fluid back into the MC.

Where are these holes in the MC? I have a 81 cx500c with a single piston and a clear plastic reservoir. My pads are dragging slightly. I just replaced the fluid, old stuff didn't look too bad. I'm not sure what to do to get the pads completely free.

They should be in the bottom of the MC. One should be obvious since it sucks the fluid in. The other should be slightly to the left.

Is it better to rebuild a 25+ year old MC or replace the whole assembly with a new one from Ebay? I saw one there for $50. A plus is no more plastic cup, all metal casting. You can even get one in chrome. Where can you find a rebuild kit anyway?

http://cgi.ebay.com/ebaymotors/_Motorcy ... 240%3A1318

Personally I'd go with the new one.Re-building an old one is not a bad solution if one has to but as you say they are 25+ years old

On a recommendation from Blindstitch,I replaced my MC with one from ebay. No regrets, it was easy to bleed and works fine. It cost less than a Honda rebuild kit with a new reservoir, plus, it's not 25+ years old.

Also, on the original Honda MC, the return hole in the master was impossible to see due to cloudy fluid, and even when flushed and cleaned, you really had to be looking to see it.

Thanks guys. Looks like I have my decision. Time to start aquiring parts to rebuild the front brakes once the forks are done.