| Posted: 29 Sep 2009 22:31 | [?] |
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Well like the tile says I just finished installing a Brembo rear master cylinder off of a 2004 Aprilia Tuono. As some of you may know I did the DIY Brembo hidden rear caliper mod last Monday and was not satisfied with the performance gains, so I decided to add a larger master cylinder to really give the Brembo caliper some driving force.
Ok, so like I said I started with a Brembo MC off of a 2004 Aprilia Tuono. 
I had to manufacture a plunger for the MC because the Brembo MC has a tapered plunger so you are not able to use the OEM plunger from the Buell. So I went to the heard wear store and bought a bolt the same size as the OEM Buell plunger and got to work. OEM plunger left, soon to be plunger right 
Finished product 
Plunger with Buell OEM hard wear installed 
I had to taper the plunger to prevent it from contacting the inside of the cylinder due to a pitch difference you encounter when mounting the Brembo master cylinder. Pitch difference/ deviation between the MC and the lever. 
The deviation is caused because the mounts for the Brembo MC are not threaded like the OEM mounts were so you have to affix the MC to the rear set via locking nuts so you are unable to gain proper alignment. This is not really an issue if you taper the plunger like I did because adequate articulation at the piston is gained because of the tapering. So once you get the plunger figured out it is pretty strait forward, you just install it and then bleed your brakes. Well here is the finished product. 
Ho, and as for performance all I can say is wow!!! It actually feels like a brake and not like a peace of wood now, and I no longer have to apply massive amounts of force to the rear lever to get it to work. So if you plan on doing the Brembo hidden rear caliper mod and would like to add performance as well as looks than I recommend incorporating a brembo MC to the mix. |
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| Posted: 29 Sep 2009 22:56 | [?] |
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Moderator Join Date: May 2008 |
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| I think you should sell a kit! | |
| Posted: 29 Sep 2009 23:02 | [?] |
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Quote:
I think you should sell a kit! mehhh, nothing was done that would require any real skill so for now I will just tell you how to do it. Besides, you get a more satisfying feeling when you finish if you did it all by yourself. 
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| Posted: 29 Sep 2009 23:30 | [?] |
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Hey Stevenc150, you should add this to your 120 + helpful threads, thread 
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| Posted: 29 Sep 2009 23:48 | [?] |
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Registered User Join Date: Jan 2009 |
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Great write up Nitto12ss,
Couldn't you have waited 'til I finished my hidden caliper mod cause now I wanna jump on this project right now. haha QUESTION!! So with the offset does the plunger rub in the cylinder at all? |
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| Posted: 29 Sep 2009 23:58 | [?] |
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Quote:
QUESTION!! So with the offset does the plunger rub in the cylinder at all? It will if you do not taper the plunger like I did. It actually rubs the cert clip, but this is a custom job so it will require custom parts. Do yourself a favor if you decide to tackle this project and take the rear set off and and attach the new MC to it. Then when you are fabricating the plunger it is easy to install and take back out when testing for fitment. The whole thing took me about 2 and 1/2 hours to do from start to finish and that includes the trip to the hard wear store. |
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| Posted: 30 Sep 2009 00:10 | [?] |
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Quote:
Do yourself a favor if you decide to tackle this project and take the rear set off and and attach the new MC to it. Good thinking. I'm strongly considering doing this mod! Price estimate? |
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| Posted: 30 Sep 2009 00:16 Last Edited By: nitto12ss | [?] |
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The total for me was > $40
$34 shipped for the MC and about $5 for the nuts and bolts. |
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| Posted: 30 Sep 2009 00:44 | [?] |
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| Not bad! I'm looking into it now. | |
| Posted: 30 Sep 2009 00:53 | [?] |
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Quote:
Not bad! I'm looking into it now. If you have not started yet with the rear caliper I would wait and do it all at once. Also be sure to wipe off all brake fluid as soon as possible when it gets on your bike(and it will)as it is a very corrosive material and will eat at your paint/powder coat if left on for extended periods of time. |
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| Posted: 30 Sep 2009 01:00 | [?] |
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Registered User Join Date: Jan 2009 |
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My fluid resevoir was leaking under my seat and dripped all over my swing are. Ruined my pain terribly!!  thiinking about getting a whole new swing arm or trying to powder coat mine to match the rest of the bike.
Yeah I'm still waiting on my ASB bracket. Then I'm might do it all at the same time. |
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| Posted: 30 Sep 2009 01:03 | [?] |
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| Buy the rattle can touch up paint from ASB, it matches perfectly. I used it to fix my swing arm after my low side and you cant even tell it happened now. | |
| Posted: 30 Sep 2009 01:14 | [?] |
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Registered User Join Date: Jan 2009 |
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| REALLY!?!?! Cause my bike looks like shit seriously! I'll pick some of that up too lol | |
| Posted: 30 Sep 2009 05:22 | [?] |
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Quote: Paired it with the Hidden Rear Brembo Caliper link. Hey Stevenc150, you should add this to your 120 + helpful threads, thread 
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| Posted: 30 Sep 2009 05:42 | [?] |
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Quote:
Paired it with the Hidden Rear Brembo Caliper link. Thanks brotha, I kinda took the time to do the writeup for that reason. |
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| Posted: 30 Sep 2009 06:01 | [?] |
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another rep point cause YOU ROCK.
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| Posted: 30 Sep 2009 06:06 | [?] |
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Me or Steven, cuz he is cool to, but I think he has enough rep 
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| Posted: 30 Sep 2009 06:17 | [?] |
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You know its kinda funny that this tread has gotten 16 comments in a few hours and my thread on the Front Master swap has zero comments. Kinda strange considering the front master swap is probably one of the best bang for the buck mods you can do to the bike. Just an observation 
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| Posted: 01 Oct 2009 22:17 | [?] |
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I went back to the drawing board on the mounting system after some safety concerns were raised by Point Doc and BrettXb12r. Need less to say they convinced me so with there suggestions carried out I present to you the new and improved mounting system.
So I got a Helicoils kit in metric size M6-1.0 it comes with everything you will need, 1/4 tap, M6 helicoils, and the installation tool. 
Luckily the holes on the Brembo MC are 1/4 so all you have to do is tap it and then install the helicoils. 
then I used 3 washers per mount to correct the alignment issue between the MC and the lever. 
3 washers is about all you can get away with due to the space limitations, but it corrects the alignment problem reasonably well, but 4 washers would have been ideal. 
I also affixed a spring to the plunger connecting to a zipty on the MC to keep the plunger in place and prevent it from falling out. 
This is a better and safer way to go about mounting the MC as it corrects the alignment issues which could cause binding and lead to an accident, so if you are going to do this mod you should mount the MC in a similar fashion. |
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| Posted: 28 Nov 2009 22:31 | [?] |
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nitto:
When you did this mod did you use the stock buell fluid reservoir? The brembo one that came with my caliper is smaller. Just wondered if it makes a difference. thanks. |
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| Posted: 29 Nov 2009 05:18 | [?] |
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| I had the same question. I don't really think it makes a difference, personally I used the stock unit so I could utilize the stock mounting position. | |
| Posted: 30 Nov 2009 10:14 | [?] |
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Registered User Join Date: Nov 2009 |
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| Other that the Aprilia any other bikes that I could find this upgrade on? I have found several master cylinders on ebay but very few have the banjo bolt in the same place as the Buell | |
| Posted: 30 Nov 2009 17:55 | [?] |
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Mcdonald1983,
from what I was able to fined when I looked there were some Ducati models that also had the banjo bolt on top of the mc. You just have to shop around and the mc with the banjo bolt on the side should work provided you can get enough slack from the rear brake sensor. |
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| Posted: 01 Dec 2009 04:18 | [?] |
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there is a used ducati MC on ebay right now with a buy it now price of $40. It comes with the MC with the banjo bolt in the correct location and a brake line.
Just type in "Ducati rear master" in the search bar. |
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| Posted: 24 Dec 2009 22:39 | [?] |
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nitto12ss:
I am currently working on this mod and have my brakes all torn apart. Im at the point of putting the new master cylinder on, but when I try to attach the sensor cable to the top of the mc the, i guess its the banjo bolt wont go in. I have two brembo master cylinders and it wont go into either. Did you have to do anything special to get yours in? I have already retapped the two holes to attach it to the bike and put helicoils in and everything. Looking forward to any help. thanks alot. |
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| Posted: 25 Dec 2009 04:18 | [?] |
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Quote:
nitto12ss: I am currently working on this mod and have my brakes all torn apart. Im at the point of putting the new master cylinder on, but when I try to attach the sensor cable to the top of the mc the, i guess its the banjo bolt wont go in. I have two brembo master cylinders and it wont go into either. Did you have to do anything special to get yours in? I have already retapped the two holes to attach it to the bike and put helicoils in and everything. Looking forward to any help. thanks alot. Hmmmmmm, mine went right it. Do you have enough slack in the cable? |
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| Posted: 25 Dec 2009 17:10 | [?] |
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Posts: 219 Reputation: 6 [?] User Rank: Major
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| I have pulled the cable all the way off the bike because the mc I bought came with alittle longer one. I am also changing the pads in the brembo caliper. I am not sure what is up with it but I will try a couple different things. If it doesn't work I'll order a new brake switch and try mocking something up. Maybe the threads either in the mc or on the switch bolt are screwed up. Not sure but thanks for the help. I'll keep ya posted. | |
| Posted: 25 Dec 2009 17:38 Last Edited By: nitto12ss | [?] |
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If you just need a quick fix you could just put a regular banjo bolt in there. Your rear brake switch will become nonfunctional but the brakes will work. Keep me posted
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| Posted: 25 Dec 2009 18:32 | [?] |
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Guys, you do know you can buy all these duc/brembo parts new for about the same price as S/H, there is a Brembo dealer on ebay(sells in the USA, not china or thailand)
His username is "dream-duc" and you find his new price are most time as cheap or cheaper than genuine ducati parts(even tho there just brembo anyway) I bought my rear caliper from him and im about to order my MC from him, very very good service |
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| Posted: 29 Dec 2009 00:36 | [?] |
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Registered User Currently Offline Join Date: Jul 2008 |
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| nitto12ss: Did you have to make a new plunger or could you have gotten a stock ducati one? I am at that point and trying to get this thing back together. | |
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