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1999 Mule 2500 Master Cylinder Rebuild

Mikey

By Mikey
in Kawasaki UTV SxS Forum

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Mikey

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My master cylinder is leaking from the rod that goes to brake pedal. I had planed on replacing it with a new one as I had routinely seen them on eBay for $109 but now that I need one the cheapest used cykinder is $134. Does anybody know where I might find a seal kit for the cylinder?  Are all Mule cylinder's 11/16" diameter?

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Mikey Contributor

Mikey

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@Travis Thanks. Yes it is a Nissin master cylinder (MC) with an 11/16" bore. I decided to buy a used MC from an later model Mule. It is diferent than mine in that the push rod is detached from the piston in the MC. On my MC the push rod is one with the piston in the MC which is a bad design as it will tend to cock the piston in its bore during brake application. I am hoping the newer designed MC will fit my 2500 or that I can modify the push rod to work while keeping it detached from the piston. $40 on ebay. I did find some Nissin rebuild kids but these were $40 or more and did not seem to match the components inside my MC. Wish me luck.

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Mikey Contributor

Mikey

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@Travis 

 

Thanks Travis,

Yes, all figured out and back on the trail again. I stumbled accross https://www.powersportsnation.com/ while looking at ebay ads and found a good condition $40 master cylinder from them. It arrived in only two days. I disassembled it, cleaned it, reassembled it  and installed it. Works like new again.

While in there I found my brake pedal return torsion spring was broken so ordered a new one off eBay that arrived today for installation tomorrow.

All good. Thanks for the follow up.   Mike

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