Under tank to handlebar master cylinder conversion

Under tank to handlebar master cylinder conversion
16 January 2023
Under tank to handlebar master cylinder conversion

A popular modification for owners of R series classic BMW's who have the under tank brake master cylinder fitted as standard is to move the master cylinder to the handlebars.

This modification replaces the original cable operation meaning more positive and consistant braking performance, alongside the fitment of a master cylinder with a smaller bore size more suitable for the performance of the standard brake caliper.

There are a few ways of doing this, with some being easier to achieve than others mostly due to parts availability. 

The easiest way is by using a Monolever (1985 onwards) handlebar clamp. No cables are required as this way uses the original twin pull pre 1981 cables.

See the table below for the part description and part number to achieve the conversion:

 

Part description

Motorworks part number

Monolever clamp (fitted to bikes built from 1985 onwards)

HAA54461 

1981 onwards lever and lever pivot

HAA42555 & SSA30870

Top cover to suit Monolever clamp

HAA57039

Top cover screw

SSA32668

Master cylinder to clamp bolt x2

SSA22418 (M5x20) x2

Master cylinder (12mm or 13mm)

BRA10784 13mm / BRA02369 12mm

Upper brake hose

Check handlebar height

Throttle bevel and chain

40mm carbs use HAA33535D / 32mm carbs use HAA33535H

Brake light switch (torpedo type)

ELA59569 (connectors require modification)

Hose splitter (3 port)

BRA41568

 

When carrying out changes like this, it is important to not overlook the condition of the other components of the braking system currently fitted, such as your calipers, brake pads and brake discs. 

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