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  #1 (permalink)  
Old 02-23-2017, 08:13 AM
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Jelly sludge

Everything is happenin to my bike, i guess its a part of havin a chop and doin proper maintenance. My front wheel locked up due to brake failure. Opened up master cylinder n i see jelly sludge in there. I had never opened the front ( i worked on bak but not front) since i have owned this bike. I cleaned n vacuumed the sludge out. I read to flush with alcohol ....is this right or do i need to start lookin for a rebuild kit ?

It looks like at one point dot 4 n 5 was mixed....
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Old 02-23-2017, 12:23 PM
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Mixing the two will do that!!
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Old 02-23-2017, 12:55 PM
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Flushing it will probably make it work again but I like to rebuild them after that happens, you'll be surprised how much goo you'll find and you'll be certain that none of the seals have swelled. It's cheap insurance...we are talking about your brakes after all.
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Old 02-23-2017, 02:26 PM
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This had to have happen before i was owner since i have never opened that master cylinder
Also my own fault for not checking. I flushed with alcohol and took 4 bottles to finally get clear..letting dry and doin again...will be looking for rebuild kit..then again...where is john at
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Old 04-23-2017, 04:40 PM
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I cleaned and used conpressed air to blow gunk out of master cylinder, lines, and caliper. Will not bleed. I ordered a plunger kit for the joker machine master cyl i have but i cant figure out how to remove the old one. I cant find any info on this nor any videos. The harley master cyl looks different as most hd master cyl have a c clip that holds tge plunger in...i dont see one on mine. Any help please
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Old 04-23-2017, 05:27 PM
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If I can remember correctly, I drilled a hole in the old plunger and screwed a 3 inch drywall screw into it and pulled it out..
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Old 04-23-2017, 05:40 PM
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What is the name of the part that slides in n out when the lever is moving? Would the screw go thru that n pulled?
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Old 04-23-2017, 05:48 PM
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I think you are talking about the plunger...looks like a piston in a cylinder...yes that is one of the only ways to get it out if it is stuck from gook..Mine was made of plastic and swelled up from the brake fluid, I managed to pull it out, and sand it down and reuse it..try not to drill all the way through it if you want to do the same..you can still pull it out even if it is made of metal..
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Old 04-23-2017, 05:53 PM
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Replacement Parts - Classic Control

This is the only thing available for my set up....the outer "piston" is not sold...thats why im confused...thanks for your patients shovel
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Old 04-23-2017, 06:28 PM
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Mine is an after market master cylinder and it was for the rear, and didn't have a lever just ..a rod that pushes on the one plunger, so yours is a little different..since your lever acts sort of like a cam, that pushes the first piston.. metal piston hopefully..then drilling into it doesn't seem like a big deal..I would just drill into it like 1/8 of an inch or so, just enough for a screw to snag it.....a fine threaded screw,..or better ..a tap... so you don't have to drill too deep..but probably wouldn't matter if you drilled deep. This is just a suggestion.. I would feel more comfortable looking at it myself..seems like it would be ok though....They probably don't sell this part because it never wears out....but having a hole in it is not going to affect it's function..if you drilled all the way through the main plunger, then yes..
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Last edited by Shovel52; 04-23-2017 at 06:36 PM..
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  #11 (permalink)  
Old 04-24-2017, 02:39 AM
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with the lever off but the rest of the master cylinder assembled with the lid on put an air line in the hole the brake line screws into...pressurise it and it will pop the plunger out.
but be careful as when it pops it will fly out like a .357 round on the range.....wrap it in lots of rags to stop it taking ya eye out
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Old 04-27-2017, 06:26 PM
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I was able to replace plunger...now i still cant bleed this fuker.
Im usinga brake bleeder, bleeder open on caliper....nothing comes out....
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Old 04-27-2017, 06:49 PM
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There are other threads on this problem...you may have to pump it and then crack it at each fitting starting with the master cylinder ...then the banjo bolt and finally the caliper..then try your
bleeder....also make sure that the plunger is in front of the bleeder hole..valve ..what ever.. and not behind it..gotta play with it.. would also be curious as to how you removed the plunger..
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Old 04-27-2017, 07:05 PM
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I ended up emailing joker machine...i pushed in the piston bout half way and pulled the rubber boot out...that rubber was so bad i took it out in pieces. New plunger looks different. Man im confused on position of plunger, i really thought it was as easy as sliding it in , this new plunger was super easy to install...im gonna just start crackin bolts...i suspect a large air pocket or plunger installed incorrectly...side note...at beginning i could see little air bubbles in fluid at master cyl....after a couple of cracks at bleeder, dont see any now
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Old 04-27-2017, 07:39 PM
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Cracked top bleeder of my single disc caliper setup..no fluid...cracked bottom..nothing...tried bleeder on both nothing...cracked banjo at master cylinder...no fluid...thought i should be getting atleast a drip, so i took the whole bolt out and no fluid coming out. What i do wrong
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