Can anyone recommend a firm in Australia (preferably in Sydney) which is experienced in sleeving master cylinders? I want to have a 14mm front brake master cylinder sleeved to 11mm. I've done some internet research but the resulting info was pretty old, so I'm hoping someone can offer some recent testimonials. I understand that the process was pioneered by Halray of Lismore. The company is still in business, but now only makes the tools and equipment for carrying out the work. I also understand that there are now many clutch & brake shops which offer the service (likely using the Halray gear), but I haven't come across any motorcycle-related reports. Imagining the work involved, I thought I might even be able to do it myself. However, there could be some pitfalls which I don't fully appreciate. If the cost is reasonable, I'd rather have it done by someone who has done it before! Any input welcome. Thanks & regards, James
I know Powerbrakes in SA do it, not sure if they can go that small though. https://www.powerbrakes.com.au/wheel-and-master-cylinder-reconditioning Might be easier to find a smaller brake master off another bike ?
It would be far cheaper to find a cylinder from another bike in the smaller size. What are you trying to achive? Do you want it for front or rear? Bit more info would help. Brembo make an 11mm brake m/c, also lots of dirt bikes and chinese pit bikes use that size.
Thanks for the replies all. I am at the 'sleeving stage' because I can't find a suitable 11mm master cylinder. However, this may be an opportune moment to ask for help in that department. The master cylinder should be (or closely resemble) that of a Kawasaki KR-1 (14mm bore as standard). This has an integral reservoir which is round and also slightly angled (so that the reservoir is level, despite the handlebars being angled downwards). This is what it looks like: Nissin makes a generic aftermarket 'retro' assembly which looks very similar, but it uses a different type of brake lever and the smallest bore available is 1/2". Kawasaki's recent W650 and W800 models also use a master cylinder which looks very similar, but the reservoir is not angled and the bore is also too big (14mm or 5/8" - can't remember which). The brake caliper I intend to use would work best with an 11mm master cylinder. I could use a brake caliper with larger pistons so as to make a 1/2" master cylinder suitable, but that would mean spending more money (on both master cylinder and caliper). If sleeving proves to be out-of-the-question, I could use a remote-reservoir Nissin 11mm master cylinder I already have, but that is not really the look I want. As far as I can tell, the sleeving option is very cost effective and would give me the desired appearance. If anyone knows of any 11mm front brake master cylinders which look like the one in the picture above, please let me know! I may also try following up some the (8+ year old) local sleeving leads I have learned about so far. Thanks & regards, James
Any 'good' machinist should be able to turn up a sleeve to reduce the dia, press fit it to your cylinder and hone to the correct size. Then you only need to drill the fill and bleed holes and buy yourself the right size piston and rubbers.
Found a list of 11mm brake master cylinder's Make,Model,Year Honda,CR125R A,1999 Honda,CR125R A,2000 Honda,CR125R A,2001 Honda,CR125R A,2002 Honda,CR125R A,2003 Honda,CR125R A,2004 Honda,CR125R A,2005 Honda,CR125R A,2006 Honda,CR125R A,2007 Honda,CR250R A,1999 Honda,CR250R A,2000 Honda,CR250R A,2001 Honda,CR250R A,2002 Honda,CR250R A,2003 Honda,CR250R A,2004 Honda,CR250R A,2005 Honda,CR250R A,2006 Honda,CR250R A,2007 Honda,CR500R A,1999 Honda,CR500R A,2000 Honda,CR500R A,2001 Honda,CR80R A,2000 Honda,CR80R A,2001 Honda,CR80R A,2002 Honda,CR80RB A,2000 Honda,CR80RB A,2001 Honda,CR80RB A,2002 Honda,CR85R A,2003 Honda,CR85R A,2004 Honda,CR85R A,2005 Honda,CR85R A,2006 Honda,CR85R A,2007 Honda,CR85RB A,2003 Honda,CR85RB A,2004 Honda,CR85RB A,2005 Honda,CR85RB A,2006 Honda,CR85RB A,2007 Honda,CRF150R,2012 Honda,CRF150R 2A,2009 Honda,CRF150R A,2007 Honda,CRF150R A,2008 Honda,CRF150R A,2009 Honda,CRF150R A,2012 Honda,CRF150RB 2A,2009 Honda,CRF150RB A,2007 Honda,CRF150RB A,2008 Honda,CRF150RB A,2009 Honda,CRF150RB A,2012 Honda,CRF250R,2012 Honda,CRF250R A,2004 Honda,CRF250R A,2005 Honda,CRF250R A,2006 Honda,CRF250R A,2009 Honda,CRF250R A/A,2004 Honda,CRF250R A/A,2005 Honda,CRF250R A/A,2006 Honda,CRF250R A/B,2005 Honda,CRF250R A/B,2006 Honda,CRF250X A,2004 Honda,CRF250X A,2005 Honda,CRF250X A,2006 Honda,CRF250X A,2007 Honda,CRF250X A,2008 Honda,CRF250X A,2009 Honda,CRF250X A,2012 Honda,CRF250X A/A,2005 Honda,CRF250X A/A,2006 Honda,CRF250X A/A,2007 Honda,CRF250X A/A,2008 Honda,CRF250X A/B,2006 Honda,CRF250X A/B,2007 Honda,CRF250X AC,2004 Honda,CRF250X AC,2005 Honda,CRF250X AC,2006 Honda,CRF250X AC,2007 Honda,CRF250X AC,2008 Honda,CRF250X AC,2009 Honda,CRF250X AC,2012 Honda,CRF250X AC/A,2005 Honda,CRF250X AC/A,2006 Honda,CRF250X AC/A,2007 Honda,CRF250X AC/A,2008 Honda,CRF250X AC/B,2007 Honda,CRF450R,2012 Honda,CRF450R 2A,2008 Honda,CRF450R 2A/A,2008 Honda,CRF450R A,2002 Honda,CRF450R A,2003 Honda,CRF450R A,2004 Honda,CRF450R A,2005 Honda,CRF450R A,2006 Honda,CRF450R A,2007 Honda,CRF450R A,2008 Honda,CRF450R A/A,2004 Honda,CRF450R A/A,2005 Honda,CRF450R A/A,2006 Honda,CRF450R A/A,2007 Honda,CRF450R A/A,2008 Honda,CRF450R A/B,2005 Honda,CRF450X A,2005 Honda,CRF450X A,2006 Honda,CRF450X A,2007 Honda,CRF450X A,2008 Honda,CRF450X A,2009 Honda,CRF450X AC,2005 Honda,CRF450X AC,2006 Honda,CRF450X AC,2012 Honda,XR250R A,2000 Honda,XR250R A,2001 Honda,XR250R A,2002 Honda,XR250R A,2003 Honda,XR250R A,2004 Honda,XR250R A/A,2004 Honda,XR250R A/B,2004 Honda,XR250R AC,2000 Honda,XR250R AC,2001 Honda,XR250R AC,2002 Honda,XR250R AC,2003 Honda,XR250R AC,2004 Honda,XR250R AC/A,2004 Honda,XR250R AC/B,2004 Honda,XR400R A,2000 Honda,XR400R A,2001 Honda,XR400R A,2002 Honda,XR400R A,2003 Honda,XR400R A,2004 Honda,XR400R A/A,2003 Honda,XR400R A/A,2004 Honda,XR400R A/B,2004 Honda,XR400R A/C,2004 Honda,XR400R AC,2000 Honda,XR400R AC,2001 Honda,XR400R AC,2002 Honda,XR400R AC,2003 Honda,XR400R AC,2004 Honda,XR400R AC/A,2003 Honda,XR400R AC/A,2004 Honda,XR400R AC/B,2004 Honda,XR400R AC/C,2004 Honda,XR650R A,2000 Honda,XR650R A,2001 Honda,XR650R A,2002 Honda,XR650R A,2003 Honda,XR650R A,2004 Honda,XR650R A,2005 Honda,XR650R A,2006 Honda,XR650R A,2007 Honda,XR650R A/A,2003 Honda,XR650R A/A,2005 Honda,XR650R A/B,2005 Honda,XR650R AC,2000 Honda,XR650R AC,2001 Honda,XR650R AC,2002 Honda,XR650R AC,2003 Honda,XR650R AC,2004 Honda,XR650R AC,2005 Honda,XR650R AC,2006 Honda,XR650R AC/A,2003 Honda,XR650R AC/A,2005 Honda,XR650R AC/B,2005 Husaberg,FC 450,2005 Husaberg,FC 550,2005 Kawasaki,KLX250SF,2010 Kawasaki,KLX450A8F KLX450R,2008 Kawasaki,KLX450A9F KLX450R,2009 Kawasaki,KX100-D1 KX100,2001 Kawasaki,KX100-D2 KX100,2002 Kawasaki,KX100-D3 KX100,2003 Kawasaki,KX100-D4 KX100,2004 Kawasaki,KX100-D5 KX100,2005 Kawasaki,KX100D6F KX100,2006 Kawasaki,KX100D7F KX100,2007 Kawasaki,KX100D8F KX100,2008 Kawasaki,KX100D9F KX100,2009 Kawasaki,KX100D9FA KX100 Monster Energy,2009 Kawasaki,KX125-L3 KX125,2001 Kawasaki,KX125-L4 KX125,2002 Kawasaki,KX125-M1 KX125,2003 Kawasaki,KX125-M2 KX125,2004 Kawasaki,KX125-M3 KX125,2005 Kawasaki,KX250,2010 Kawasaki,KX250-L3 KX250,2001 Kawasaki,KX250-L4 KX250,2002 Kawasaki,KX250-M1 KX250,2003 Kawasaki,KX250-M2 KX250,2004 Kawasaki,KX250-N1 KX250F,2004 Kawasaki,KX250-N2 KX250F,2005 Kawasaki,KX250-R1 KX250,2005 Kawasaki,KX250R6F KX250,2006 Kawasaki,KX250R7F KX250,2007 Kawasaki,KX250T6F KX250F,2006 Kawasaki,KX250T7F KX250F,2007 Kawasaki,KX250T8F KX250F,2008 Kawasaki,KX250W9F KX250F,2009 Kawasaki,KX250W9FA KX250F Monster Energy,2009 Kawasaki,KX250XAFB KX250F,2010 Kawasaki,KX450D6F KX450F,2006 Kawasaki,KX450D7F KX450F,2007 Kawasaki,KX450D8F KX450F,2008 Kawasaki,KX450E9F KX450F,2009 Kawasaki,KX450E9FA KX450F Monster Energy,2009 Kawasaki,KX450EAF KX450F,2010 Kawasaki,KX500-E16 KX500,2004 Kawasaki,KX85-A1 KX85,2001 Kawasaki,KX85-A2 KX85,2002 Kawasaki,KX85-A3 KX85,2003 Kawasaki,KX85-A4 KX85,2004 Kawasaki,KX85-A5 KX85,2005 Kawasaki,KX85A6F KX85,2006 Kawasaki,KX85A7F KX85,2007 Kawasaki,KX85A8F KX85,2008 Kawasaki,KX85A9F KX85,2009 Kawasaki,KX85A9FA KX85 Monster Energy,2009 Kawasaki,KX85AAF KX85,2010 Kawasaki,KX85ABF KX85,2011 Kawasaki,KX85ACF KX85,2012 KTM,125 EXC,2001-2004 KTM,125 SX,2001-2004 KTM,125 SXS,2001-2002 KTM,200 EXC,2000-2004 KTM,200 MXC,2001-2003 KTM,200 SX,2004 KTM,250 EXC,2001-2004 KTM,250 MXC,2000 KTM,250 SX,2001-2004 KTM,250 SXC,2003 KTM,250 SXS,2001 KTM,300 EXC,2001-2004 KTM,300 MXC,2001-2003 KTM,380 EXC,2001-2002 KTM,380 SX,2001-2002 KTM,400 MXC,2002 KTM,400 SX,2001-2002 KTM,450 EXC,2003-2004 KTM,450 SX,2003-2004 KTM,520 EXC,2001-2002 KTM,520 SX,2001-2002 KTM,525 EXC,2003-2004 KTM,525 MXC,2003 KTM,525 SX,2003-2005 KTM,540 SXS,2001-2002 KTM,625 SXC,2003-2004 KTM,660 LC4 Rally,2001-2002 KTM,EXC Racing,2003 KTM,Rally Factory Replica,2003 Suzuki,DR125SE,1994 Suzuki,DR125SE,1995 Suzuki,DR125SE,1996 Suzuki,DR200SE,1996 Suzuki,DR200SE,1997 Suzuki,DR200SE,1998 Suzuki,DR200SE,1999 Suzuki,DR200SE,2000 Suzuki,DR200SE,2001 Suzuki,DR200SE,2002 Suzuki,DR200SE,2003 Suzuki,DR200SE,2004 Suzuki,DR200SE,2005 Suzuki,DR200SE,2006 Suzuki,DR200SE,2007 Suzuki,DR200SE,2008 Suzuki,DR200SE,2009 Suzuki,DR200SE,2013 Suzuki,DR250SES,1990 Suzuki,DR250SES,1991 Suzuki,DR250SES,1992 Suzuki,DR250SES,1993 Suzuki,DR250SES,1994 Suzuki,DR250SES,1995 Suzuki,DR350,1993 Suzuki,DR350,1995 Suzuki,DR350S,1993 Suzuki,DR350SE,1997 Suzuki,DR350SE,1998 Suzuki,DR350SE,1999 Suzuki,DR350SET,1990 Suzuki,DR350SET,1991 Suzuki,DR350SET,1992 Suzuki,DR350SET,1993 Suzuki,DR350SET,1994 Suzuki,DR350SET,1995 Suzuki,DR350SET,1996 Suzuki,DR-Z125 (DR-Z125L),2008 Suzuki,DR-Z125 (DR-Z125L),2009 Suzuki,DR-Z125 (DR-Z125LK3-LK4-LK5-LK6-LK7),2003 Suzuki,DR-Z125 (DR-Z125LK3-LK4-LK5-LK6-LK7),2004 Suzuki,DR-Z125 (DR-Z125LK3-LK4-LK5-LK6-LK7),2005 Suzuki,DR-Z125 (DR-Z125LK3-LK4-LK5-LK6-LK7),2006 Suzuki,DR-Z125 (DR-Z125LK3-LK4-LK5-LK6-LK7),2007 Suzuki,DR-Z125L (DR-Z125L),2008 Suzuki,DR-Z125L (DR-Z125L),2009 Suzuki,DR-Z125L (DR-Z125LK3-LK4-LK5-LK6-LK7),2003 Suzuki,DR-Z125L (DR-Z125LK3-LK4-LK5-LK6-LK7),2004 Suzuki,DR-Z125L (DR-Z125LK3-LK4-LK5-LK6-LK7),2005 Suzuki,DR-Z125L (DR-Z125LK3-LK4-LK5-LK6-LK7),2006 Suzuki,DR-Z125L (DR-Z125LK3-LK4-LK5-LK6-LK7),2007 Suzuki,DR-Z125L2 (DR-Z125L E28),2012 Suzuki,DR-Z125L2 (DR-Z125L E33),2012 Suzuki,DR-Z125L3 (DR-Z125LL3 E28),2013 Suzuki,DR-Z125L3 (DR-Z125LL3 E33),2013 Suzuki,DR-Z125LL2 (DR-Z125L E28),2012 Suzuki,DR-Z125LL2 (DR-Z125L E33),2012 Suzuki,DR-Z125LL3 (DR-Z125LL3 E28),2013 Suzuki,DR-Z125LL3 (DR-Z125LL3 E33),2013 Suzuki,DR-Z250,2001 Suzuki,DR-Z250,2002 Suzuki,DR-Z250,2003 Suzuki,DR-Z250,2004 Suzuki,DR-Z250,2005 Suzuki,DR-Z250,2006 Suzuki,DR-Z250,2007 Suzuki,DR-Z400S,2000 Suzuki,DR-Z400S,2001 Suzuki,DR-Z400S,2002 Suzuki,DR-Z400S,2003 Suzuki,DR-Z400S,2004 Suzuki,DR-Z400S,2005 Suzuki,DR-Z400S,2006 Suzuki,DR-Z400S,2007 Suzuki,DR-Z400S,2008 Suzuki,DR-Z400S,2009 Suzuki,DR-Z400SL1,2011 Suzuki,DR-Z400SL2,2012 Suzuki,DR-Z400SL3,2013 Suzuki,DR-Z400SM,2005 Suzuki,DR-Z400SM,2006 Suzuki,DR-Z400SM,2007 Suzuki,DR-Z400SM,2008 Suzuki,DR-Z400SML3,2013 Suzuki,RM125,1993 Suzuki,RM125,1995 Suzuki,RM125M,1989 Suzuki,RM125M,1990 Suzuki,RM125M,1991 Suzuki,RM125S,1992 Suzuki,RM125S,1993 Suzuki,RM125S,1994 Suzuki,RM125S,1995 Suzuki,RM250,1993 Suzuki,RM250,1995 Suzuki,RM250N (MODEL K-L-M),1989 Suzuki,RM250N (MODEL K-L-M),1990 Suzuki,RM250N (MODEL K-L-M),1991 Suzuki,RM250N (MODEL K-L-M),1992 Suzuki,RM250N (MODEL N),1989 Suzuki,RM250N (MODEL N),1990 Suzuki,RM250N (MODEL N),1991 Suzuki,RM250N (MODEL N),1992 Suzuki,RM250S,1993 Suzuki,RM250S,1994 Suzuki,RM250S,1995 Suzuki,RM80,1996 Suzuki,RM80,1997 Suzuki,RM80,1998 Suzuki,RM80,1999 Suzuki,RM80,2000 Suzuki,RM80,2001 Suzuki,RM80 (MODEL K-L-M-N-P-R),1986 Suzuki,RM80 (MODEL K-L-M-N-P-R),1987 Suzuki,RM80 (MODEL K-L-M-N-P-R),1993 Suzuki,RM80 (MODEL K-L-M-N-P-R-S),1995 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1986 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1987 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1988 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1989 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1990 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1991 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1992 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1993 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1994 Suzuki,RM80S (MODEL K-L-M-N-P-R-S),1995 Suzuki,RM85 (MODEL K2-K3-K4),2002 Suzuki,RM85 (MODEL K2-K3-K4),2003 Suzuki,RM85 (MODEL K2-K3-K4),2004 Suzuki,RM85 (MODEL K2-K3-K4),2005 Suzuki,RM85 (MODEL K2-K3-K4),2006 Suzuki,RM85L (MODEL K2-K3-K4),2003 Suzuki,RM85L (MODEL K2-K3-K4),2004 Suzuki,RM85L (MODEL K2-K3-K4),2005 Suzuki,RM85L (MODEL K2-K3-K4),2006 Suzuki,RMX250,1993 Suzuki,RMX250,1995 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1989 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1990 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1991 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1992 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1993 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1994 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1995 Suzuki,RMX250T (MODEL K-L-M-N-P-R-S),1996 Suzuki,RMX250T (MODEL T),1989 Suzuki,RMX250T (MODEL T),1990 Suzuki,RMX250T (MODEL T),1991 Suzuki,RMX250T (MODEL T),1992 Suzuki,RMX250T (MODEL T),1993 Suzuki,RMX250T (MODEL T),1994 Suzuki,RMX250T (MODEL T),1995 Suzuki,RMX250T (MODEL T),1996 Suzuki,RMX250W,1997 Suzuki,RMX250W,1998 Yamaha,OFF-ROAD - TT225L,1999 Yamaha,OFF-ROAD - TT225LC,1999 Yamaha,OFF-ROAD (Deep Purplish Blue Solid E) - TTR225L,1999 Yamaha,RT180G,1995 Yamaha,RT180H,1996 Yamaha,RT180J,1997 Yamaha,RT180K,1998 Yamaha,TTR225 - TT225RN,2001 Yamaha,TTR225 - TT225RNC,2001 Yamaha,TTR225 - TTR225M,2000 Yamaha,TTR225 - TTR225MC,2000 Yamaha,TTR225 - TTR225P,2002 Yamaha,TTR225 - TTR225PC,2002 Yamaha,TTR225 - TTR225R,2003 Yamaha,TTR225 - TTR225RC,2003 Yamaha,TT-R225 - TTR225S,2004 Yamaha,TT-R225 - TTR225SC,2004 Yamaha,TTR225 (Deep Purplish Blue Solid E) - TTR225N,2001 Yamaha,TTR230 - TTR230A,2011 Yamaha,TT-R230 - TTR230T,2005 Yamaha,TT-R230 - TTR230TC,2005 Yamaha,TT-R230 - TTR230V,2006 Yamaha,TT-R230 - TTR230W,2007 Yamaha,TTR230 (DEEP PURPLISH BLUE SOLID E) - TTR230X,2008 Yamaha,TTR230 (DEEP PURPLISH BLUE SOLID E) - TTR230Y,2009 Yamaha,WR 250F - WR250FA,2011 Yamaha,WR 450F - WR450FA,2011 Yamaha,WR250F,2009 Yamaha,WR250F - WR250FP,2002 Yamaha,WR250F - WR250FR,2003 Yamaha,WR250F - WR250FS,2004 Yamaha,WR250F - WR250FT,2005 Yamaha,WR250F - WR250FV,2006 Yamaha,WR250F - WR250FW,2007 Yamaha,WR250F - WR250FX,2008 Yamaha,WR250F (DEEP PURPLISH BLUE SOLID E) - WR250FY,2009 Yamaha,WR426F - WR426FP,2002 Yamaha,WR450F - WR450FR,2003 Yamaha,WR450F - WR450FS,2004 Yamaha,WR450F - WR450FT,2005 Yamaha,WR450F - WR450FW,2007 Yamaha,WR450F - WR450FX,2008 Yamaha,WR450F - WR450FY,2009 Yamaha,XT350 - XT350M,2000 Yamaha,XT350 - XT350MC,2000 Yamaha,XT350A,1990 Yamaha,XT350B,1991 Yamaha,XT350BC,1991 Yamaha,XT350D,1992 Yamaha,XT350E,1993 Yamaha,XT350F,1994 Yamaha,XT350G,1995 Yamaha,XT350H,1996 Yamaha,XT350J,1997 Yamaha,XT350JC,1997 Yamaha,XT350K,1998 Yamaha,XT350KC,1998 Yamaha,XT350L (PURPLISH WHITE SOLID 1),1999 Yamaha,XT350N,1985 Yamaha,XT350S,1986 Yamaha,XT350T,1987 Yamaha,XT350U,1988 Yamaha,XT350W,1989 Yamaha,YZ 85 - YZ85A,2011 Yamaha,YZ125 - YZ125P,2002 Yamaha,YZ125 - YZ125R,2003 Yamaha,YZ125 - YZ125S1,2004 Yamaha,YZ125 - YZ125T1,2005 Yamaha,YZ125 - YZ125V,2006 Yamaha,YZ125 - YZ125W1,2007 Yamaha,YZ250 - YZ250P,2002 Yamaha,YZ250 - YZ250R,2003 Yamaha,YZ250 - YZ250S1,2004 Yamaha,YZ250 - YZ250T1,2005 Yamaha,YZ250 - YZ250V,2006 Yamaha,YZ250 - YZ250W1,2007 Yamaha,YZ250F - YZ250FP,2002 Yamaha,YZ250F - YZ250FR,2003 Yamaha,YZ250F - YZ250FS,2004 Yamaha,YZ250F - YZ250FT,2005 Yamaha,YZ250F - YZ250FV,2006 Yamaha,YZ250F 50TH ANNIVERSARY - YZ250FSPV,2006 Yamaha,YZ426F - YZ426FP,2002 Yamaha,YZ450F - YZ450FR,2003 Yamaha,YZ450F - YZ450FS,2004 Yamaha,YZ450F - YZ450FT,2005 Yamaha,YZ450F - YZ450FV,2006 Yamaha,YZ450F - YZ450FW,2007 Yamaha,YZ450F 50TH ANNIVERSARY - YZ450FSPV,2006 Yamaha,YZ85,2002 Yamaha,YZ85 - YZ85P,2002 Yamaha,YZ85 - YZ85R,2003 Yamaha,YZ85 - YZ85S,2004 Yamaha,YZ85 - YZ85T,2005 Yamaha,YZ85 - YZ85V,2006 Yamaha,YZ85 - YZ85W1,2007 Yamaha,YZ85 - YZ85X,2008 Yamaha,YZ85 - YZ85Z,2010 Yamaha,YZ85 (DEEP PURPLISH BLUE SOLID E) - YZ85Y,2009 Yamaha,YZ85Z,2010 Yamaha,ZUMA - YW50AL,2010 Yamaha,Zuma - YW50T,2005 Yamaha,Zuma - YW50X,2008 Yamaha,ZUMA - YW50XB,2008 Yamaha,ZUMA - YW50XL,2008 Yamaha,ZUMA - YW50ZB,2010 Yamaha,ZUMA - YW50ZY,2010 Yamaha,ZUMA (BLACK METALLIC X) - YW50YB,2009 Yamaha,ZUMA (DEEP PURPLISH BLUE METALLIC C) - YW50YL,2009
You could try these guys they have been around for a while and did excellent work on my car clutch master cylinder. If they don't do it they may be able to point you in the right direction. http://sbcs.net.au/
The problem with trying to sleeve to a new size is that there are 2 parts to the sizing of the master cylinder piston. The area of the piston is for the correct force on the caliper piston.. larger diameter means slightly less pressure is required for the equivalent pad pressure... and then there is the stroke of the piston (volume of fluid moved). If the stroke or total movement of the piston isnt enough you wont have enough brake force. This is what happens when people change to twin disc setups and dont change from the single disc master cylinder and wonder why their brake performance is worse than with a single disc. The other issue is as @Murdo mentioned and that is finding the right piston and seals to mate up to the fluid holes etc in the master cylinder you are going to use, you might get lucky but Normally you would only sleeve a master cylinder that was severely pitted so you could go back to standard piston and seals. If the Nissin unit is 1/2" (12mm nominal) I would use that.. it will maybe reduce your brake pressure a little but probably wont be noticeable.
Thanks everyone for your suggestions - especially my67xr for that list . Having briefly skimmed over the list, I think most (even all?) of the bikes listed have integral reservoirs, but all of the ones I am familiar with are rectangular-ish. I forgot to mention that an additional requirement is the ability to fit the standard front brake light switch - a facility which (I think) all of the motocross bikes haven't got. All of the road-registerable bikes should have it though. I have already obtained a suitable Nissin 11mm piston kit which will work with the KR-1 master cylinder (MC just needs sleeving and a 1.5mm counterbore to fit the piston retaining washer under the circlip). However, there will be some difficulty in making an adaptor bracket for the caliper I originally wanted to use. Although the problem is not insurmountable, I am looking around for other calipers which may be better suited (and hopefully cheap!). As such, I won't be making any firm decisions about the master cylinder until I have decided on the caliper. If there is anything interesting to tell, I'll let you know! Thanks again & regards, James