Honda TRX350 Master Cylinder Rebuild
Grabbing the brake lever on your Honda ATV and not feeling pressure behind it is never a good feeling. If your Honda Rancher 350 isn’t coming to a halt as quickly as it should, it might be time to get out your toolbox and rebuild the master cylinder.
Watch the video above and follow the steps below to rebuild the master cylinder on a Honda TRX350. Use our TRX350 exploded parts diagram for additional guidance.
Tools and Supplies – Honda TRX350 Master Cylinder Rebuild
- Ratchet and extension
- 8mm, 10mm sockets
- 8mm, 10mm, 12mm wrenches
- Needlenose pliers
- Screwdriver
- Pick tool
- Circlip pliers
- Master cylinder kit
- Brake fluid
How to Rebuild Honda TRX350 Front Brake Master Cylinder
Step 1. Remove the front brake lever by taking off the pivot bolt.
Step 2. Remove the brake fluid reservoir cap.
NOTE: If the reservoir hasn’t been opened in a long time, you might need to use an impact driver to loosen the two screws in the cap.
Step 3. Remove the banjo bolt holding the brake fluid line, and have a drain pan ready to catch the old brake fluid.
NOTE: Brake fluid is harmful to body paint, so be careful when handling it and have plenty of rags or shop towels ready.
Step 4. Remove the brake fluid reservoir by taking off the two bolts holding the reservoir to the handlebars.
Step 5. Remove the old master cylinder assembly from the reservoir by taking the dust seal off the reservoir, then removing the retaining circlip and pulling out the master cylinder assembly.
Step 6. Clean the reservoir thoroughly with brake cleaner to remove all traces of dirt and debris.
NOTE: Even the smallest amount of dirt can ruin the new master cylinder’s seals, so make sure the reservoir is impeccably clean.
Step 7. Install the new master cylinder assembly, making sure the rubber seals don’t bend back on themselves. Coat the master cylinder assembly and the reservoir channel it’s housed in with brake fluid to make installation easier.
Step 8. Install the new retaining circlip and the new dust seal that came with the master cylinder kit.
Step 9. Reinstall the reservoir onto the handlebars, followed by the brake fluid line banjo bolt.
Step 10. Reinstall the brake lever, then put a smear of grease on the shaft of the lever’s pivot bolt. Tighten the pivot bolt so that the lever can move freely, then secure the bolt by fully tightening the nut on the underside of the brake lever.
Step 11. Fill the reservoir with brake fluid and bleed the system to remove air and any old fluid still left in the brake lines.
