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Front master rebuild kit not fitting!

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Old Dec 24, 2021 | 01:48 PM
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Default Front master rebuild kit not fitting!

2004 softail duce . I have a 9/16 from master cylinder , order a rebuild kit that comes with the new plunger / piston , seals . First one I get the piston won’t fit in the bore , maybe a miss packaged part , get a new one sent to me through J&P no cost . 2nd one, no dice . Tried putting the seals on the piston that fits, seals too big.

it’s stamped 9/16 on the master, I ordered a 9/16 rebuild kit but doesn’t fit. Non of it is making sense anymore . Can anyone point me in the right direction


 

Last edited by E10HD; Dec 24, 2021 at 01:51 PM.
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Old Dec 24, 2021 | 01:53 PM
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Use the old plunger with the new seals and be sure to lube them a bit with brake fluid before the install attempt. New stuff can be a bit oversized and tough to get in there, patience is key.
 
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Old Dec 24, 2021 | 01:56 PM
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Originally Posted by TwiZted Biker
Use the old plunger with the new seals and be sure to lube them a bit with brake fluid before the install attempt. New stuff can be a bit oversized and tough to get in there, patience is key.
seals off the new piston don’t fit everything is too big for the bore size
 
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Old Dec 24, 2021 | 02:28 PM
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order a rebuild kit that comes with the new plunger / piston , seals
who is the manufacturer

one on the right has a beveled edge - one on left does not (?)
-
 

Last edited by F150HD; Dec 24, 2021 at 02:32 PM.
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Old Dec 24, 2021 | 02:41 PM
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Originally Posted by F150HD
who is the manufacturer

one on the right has a beveled edge - one on left does not (?)
-
not sure it’s a generic JP part number 29-032 and that bevel is to the outside it goes from this end in, the gold one is the replacement it’s like a few thousands too big for the bore , seals seem they won’t swap over either

 
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Old Dec 24, 2021 | 02:52 PM
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I just did a 15mm rebuild kit from J&P, got hung up on a cargo ship off California, then UPS lost it in IL. So I gave up, For $2 more HD had it in stock.
 
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Old Dec 24, 2021 | 04:26 PM
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Originally Posted by Hoginedgewood
I just did a 15mm rebuild kit from J&P, got hung up on a cargo ship off California, then UPS lost it in IL. So I gave up, For $2 more HD had it in stock.
yea I’m thinking it’s got to be metric . 2 of the same rebuild kits (bikers choice) and the plungers are too big even if you take the seals off the plunger it won’t fit into the bore
 
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Old Dec 25, 2021 | 07:51 PM
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Why not just get a HD rebuild kit? I have always had good luck with HD master cylinder rebuild kits and they do not cost that much.
HD Part # 45006-96C REPAIR KIT, master cylinder (9/16 inch bore)
 
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Old Dec 25, 2021 | 08:52 PM
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Originally Posted by CoolBreeze3646
Why not just get a HD rebuild kit? I have always had good luck with HD master cylinder rebuild kits and they do not cost that much.
HD Part # 45006-96C REPAIR KIT, master cylinder (9/16 inch bore)
guess I didn’t think about a harley part kit. I over composited by just getting a new master but in Chrome 🤣

 
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Old Dec 25, 2021 | 11:23 PM
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Originally Posted by E10HD
seals off the new piston don’t fit everything is too big for the bore size
Let's try this again, use the OLD piston with the new seals, f**k the new one toss it, it's shorter anyway.

 
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