06 front Master cylinder issues - ZX6R Forum
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post #1 of 9 Old 04-09-2017, 11:40 AM Thread Starter
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06 front Master cylinder issues

I'm having lots of issues with this so I'm hoping for some help.

A couple months back, I had the bike in the shop for some new tires and the front brakes were a little squishy so they bled them and got it fixed up. They said the master seemed like it was nearing its end of life and should be replaced soon.

Fast forward about a month and it was squishy again so I bought a rebuild kit. Got it installed, bled and all was well for a few weeks and it went squishy again. I had to let the bike sit for a while and drive my truck and when I went to ride again, I had no front brake at all. I checked all around for leaks and nothing.

I'm guessing that the whole master is bad and I need to replace it. I'm looking for the best way to do this that won't break the bank. Should I just get another 06 OEM? 07+? Aftermarket? What about new lines if I do anything but 06 OEM?
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post #2 of 9 Old 04-10-2017, 10:01 AM
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The 05/06 masters have a reputation for not being that great. That said, if you just did a rebuild, I'm pretty sure you replaced anything that could be bad, unless the inside of the MC is actually pitted, causing air.

On my 06, I had a similar issue. In my case, I resolved it by finally putting all new crush washers on the lines, top and bottom (Yes, I know, I could have saved myself the trouble if I'd done that when the lines were changed!). That said, many many people prefer the larger diameter 07+ MC to your original once. I have an 07 and it's quite good.

I would say, if you're going to replace it, go with an 07 or better. Any MC will fit: some folks like the Brembo ones off an R6, but you could pretty much pick up any new radial MC and it'll work.

However, if you just rebuilt it, you may not need to replace it. It could be air leaking in somewhere else. The two culprits here are the crush washers and the caliper seals. You could do just the washers, but then if you need to pull the calipers off to rebuild them, you need to do the washers again. You could rebuild your original calipers, but, again, many folks like to upgrade these. The 07+ are much better.

If you're doing all that, might as well do SS lines, you're pulling the lines off anyway.

Logically, I ended up here when I worked on my 06.

It's not worth rebuilding the 06 MC. I bought an 09 MC. I bought 07+ calipers. I bought used SS lines from @Snazzy which were sized for an original 06. I put the lines on with the new MC and Calipers.

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post #3 of 9 Old 04-10-2017, 10:59 AM
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Basically what commiehunter said. Anyone that tracks the 05-06 seems to have replaced the MC (07+), the calipers (07+), and stainless steel lines to finish it off. You will also need a new lever from the year the MC came from.

For my 06 I did SS lines first and that produced minimal results at the lever. Then a 09+ MC and the lever became more firm but nothing crazy. After finally adding 09+ calipers the lever felt completely different. Much more firm and solid. With this setup I've ran a few trackdays where the temps hit 103 F and the lever was solid all day long. Definitely one of my favorite upgrades to my 06.



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post #4 of 9 Old 04-13-2017, 03:54 PM Thread Starter
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Thanks for the info guys. I haven't dug too much into it yet, but is it safe to assume that these are bolt-on replacements? Or are modifications needed to make the newer calipers and master fit?
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post #5 of 9 Old 04-19-2017, 09:25 AM
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Everything bots right up. The lever was the only thing that gave me an issue. The lever has to match the year span of the MC (07-08 || 09-12).
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Last edited by Kali636; 04-19-2017 at 12:51 PM.
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post #6 of 9 Old 04-19-2017, 09:35 AM
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Just to back up the reply above, 07/08 or 09-12 Master Cylinder (Or any master cylinder from R6, or other bike) will clip right on. You'll need a lever that matches the master cylinder. In some cases you may have to reposition the reservoir. I used my original reservoir when I switched to an 07 master cylinder, and updated the lever.

The calipers, 07-12 will bolt right on. No changes. I'd recommend replacing the caliper bolts. The original ones can be soft and start to strip, and you don't want to have to cut one out. If you get yours out, putting new ones in makes it easier next time.

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post #7 of 9 Old 04-25-2017, 07:02 PM Thread Starter
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Thanks for all the help. I got some calipers from an 09 that are in great condition, the master from a 13 ZX10 with only 3500 miles (partzilla xref on the part number matched, 43015-0141 CYLINDER-ASSY-MASTER,), new lines and some shorty levers on Amazon, hopefully I'll get it all installed this weekend and finally be back to riding again!
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post #8 of 9 Old 04-26-2017, 12:46 PM
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Sounds like a plan. Dont forget the new crush washers. Also, when an MC is empty you can't pump it since its only air. Try loosening the bleed bolt on the MC, put a length of clear hose, and draw vacuum until fluid just comes through the bolt. (I used my mouth, just be careful) This should prime the MC so you can pump it.
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post #9 of 9 Old 04-29-2017, 07:14 PM Thread Starter
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I have a vacuum bleeder so that made quick work of it. I love the new setup and it brakes on a dime! Zip tied the brake lever back so I can check it in the morning and make sure all is well before I start really riding it again on Monday. $200 in eBay parts was well worth it! Thanks again for the help and advice guys!
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