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 TRX350 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 Needed – Honda TRX350 Master Cylinder Rebuild

Tools

  • Ratchet and extension
  • 8mm, 10mm sockets
  • 8mm, 10mm, 12mm wrenches
  • Circlip pliers
  • Screwdriver

 

  • Needlenose pliers
  • Pick tool

Supplies

Honda TRX 350 Rancher front master cylinder rebuild

How to Rebuild Honda TRX350 Front Brake Master Cylinder

Step 1. Remove the front brake lever by taking off the pivot bolt.

Honda TRX350 front brake lever

Step 2. Remove the brake fluid reservoir cap. 

Honda Rancher 350 brake fluid reservoir

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.

Honda TRX350 brake fluid line

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.

Honda TRX 350 master cylinder rebuild

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.

Honda Rancher 350 master cylinder rebuild

Step 6. Clean the reservoir thoroughly with brake cleaner to remove all traces of dirt and debris. 

Honda Rancher TRX 350 front brake master cylinder rebuild

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.

Front master cylinder rebuild Honda ATV

Step 8. Install the new retaining circlip and the new dust seal that came with the master cylinder kit.

Honda ATV front master cylinder rebuild

Step 9. Reinstall the reservoir onto the handlebars, followed by the brake fluid line banjo bolt.

Honda Rancher ATV brake master cylinder rebuild

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.

Honda TRX 350 ATV front brake master cylinder rebuild

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.

 

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