new handlebars, old master cylinder

I searched the forum and found several helpful posts on this topic, but I'd like to get an opinion from you guys before I buy anything. I've got a 1981 KZ440 LTD, and I changed the handlebars from the original ape hangers to Emgo bars (#23-12563). When the bike is upright and level, the master cylinder is tilted, but it doesn't seem TOO bad. However, when the bike is at rest on the side stand with the bars turned to the left and locked, the master cylinder sits at a crazy angle, steeper than 45 degrees. With the bars to the right, the m.c. is almost perfectly level. Judging from the photos, does the master cylinder seem too pitched when the bike is level? When the bike is resting on the kickstand, does the angle of the m.c. matter? I see a few new ones for sale online in my size (14mm bore for a 7/8" bar) with a more suitable position, for $40 - $50. To buy or not to buy, that is the question.
By the way, I'm new here. This is my first post. I've been reading this forum like crazy for the last month or so. I really appreciate all the helpful advice given here. Thanks in advance.

When the master cylinder is tilted, eventual failure of the cap gasket will likely allow brake fluid to leak out and do its usual paint-eating damage.

Imo, it's best to have the master cylinder positioned so that the fluid level remains below the cap gasket.




As I recall, Kaws with stock ape-hangers fitted specially shaped master cylinders (and brake levers) conforming to the bar angles in order to retain level position of the caps.

Good Fortune!

Looks like the bars are too far forward. Do you like it like that? The MC shouldn't have a problem if it isn't starving when riding. APE hangers, I laugh every time I see them. My daughter thinks they're stupid looking. I couldn't ride like that. My daughter when she was 7 told a biker I know, his hog sounds like a bean fart. I just smiled.
Steve

The bars look like they're pushed forward in the photo, but that's just the photo. They're positioned normally and feel great -- so much better than the original bars. I don't know how anyone ever rode in that unnatural position.
Even if the master cylinder would work at an angle, I've decided that it would drive me bananas knowing that the brake fluid is trying its best to leak out of the reservoir while the bike is parked and locked. So I'm going for a new m.c. I think I'll post my progress here, just in case someone else is thinking of doing the same thing in the future. I see the new master cylinders have a different electrical connection, so there is that problem to fix. And then I'll need a shorter upper brake line. Thanks for your opinions, Patton and swest.

Mine is not stock. I need a new gasket and just found one on line. This one has a switch built in and I didn't like the old splitter and wimpy lock for the forks. This is what I did.

Got my new master cylinder and new stainless upper brake line (11 inches) from Z1E. Do you guys recommend putting anything on the threads of the banjo fittings before threading them into the hose? Brake fluid? Teflon tape? Thanks.

They shouldn't leak without anything. If they do it's better to know now.
Steve

Wiring the new Br light switch should be fairly simple, if the new Fr Br mc has a built-in brake light switch. You could re-use the wiring from the old Fr Br switch --- just cut off the switch. Then you'd need a couple of female terminals, heat shrink wrap & terminal covers.

Fr Br mc 12.7mm single disk --- black powder-coated w chrome lever
Dual disk: 14mm or 16mm

gwyon wrote: ... Do you guys recommend putting anything on the threads of the banjo fittings before threading them into the hose? Brake fluid? Teflon tape? Thanks.

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When tightened, brake fluid doesn't contact the threads.

Tightening the threads serves to press and hold the tapered end into its seat inside the line fitting. Thereby creating a leak-free connection without any of the pressurized fluid ever reaching the threads.

Good Fortune!

Which master cylinder did you get? I have to do the same thing.

Found it on ebay, from usa-motorcycles-inc in Miami, FL. Quick shipping, seems like good quality so far.


martin_csr -- thanks for the advice about the switch wiring. I wish I could find something more elegant than just two female terminals to make the connection at the master cylinder. Some kind of plug would be nice. I asked the m.c. manufacturer about it, and they suggested the same thing you did.
Thanks to swest and Patton too.

A 2-pin connector of some sort seems like a good idea. The switch on that aftermarket mc looks similar to the switches found many modern bikes, so there might be a connector available. ???

I looked at the parts diagrams of a late model ZX600 & Vulcan 500 to see what type of stock connector there might be. Each handlebar control assy has a pigtail w a couple of flag terminals --- I'm pretty sure they're for the brake switch.

I didn't see anything at DennisKirk. CycleTerminal.com has various black terminal covers. They also have black connector covers listed on the main connector page: the small or medium size might fit over the brake switch --- not sure how it would look, though. I used one over the voltage regulator connector to protect it from dirt & grime. The connector is directly above the swing arm, so it gets pretty dirty there.