Brake master weirdness

[ILoveThumpers]

Has anyone ever ran across a brake master cylinder that can't be rebuilt? The manual for my GN has the exploded view and procedure for rebuild, but there's supposed to be a circlip holding in the whole mess. Mine appears to be held in by the casting itself.

I'll post a pic once I get home, but basically, I can't see any kind of removable part that might let the plunger/piston/spring pass through the opening.

I'm beginning to think this must be some kind of aftermarket replacement part, not a Suzuki OEM or something.

Does such a thing exist? (A brake master that can't be rebuilt)

-Deek

 

[rockcitycafe]

keep digging, it's in there

 

[coyote13]

Yeah, chances are it's just buried under crud.

 

[ILoveThumpers]

Sadly, this is not the case...

-Deek

 

[hillsy]

That "casting" around the piston rod has to come out. Otherwise there is no way the MC could have been made in the first place (they are line bored from the lever side).

Check there isn't a pin or grub screw holding that casting on, then push a drift through the cable hole and press the piston back out.

EDIT: on 2nd thoughts that "casting" is probably just a stuck washer.

 

[rockcitycafe]

try setting the retaining washer lower a bit by tapping a small flathead screwdriver around it, that should expose the retaining ring, looks like it may not be a snap ring, but the same kind of ring used on wristpins... maybe someone rebuilt it once and installed a different clip by mistake

 

[Bert Jan]

if it are two different parts, they are able to come loose. it could not have been made out of one piece..

 

[ILoveThumpers]

try setting the retaining washer lower a bit by tapping a small flathead screwdriver around it...

Going to try this with a small punch tonight. If that doesn't work, I'll drill 3 holes, tap them and make a makeshift puller out of some machine screws.

if it are two different parts, they are able to come loose. it could not have been made out of one piece..

Right, I guess what I was trying to say (poorly, obviously) is that maybe it was a pressed-in piece that wasn't meant to be taken apart... some kind of "safety" feature to prevent boneheads from killing themselves with poor rebuild skills.

The other thing I thought of was that maybe the opposite end threads off and I can't see the seam for all the snot all over it.

Whatever the case, I'll have it apart tonight one way or another.

-Deek

 

[ILoveThumpers]

Okay! So the previous owner was at the same time resourceful and very, very dumb.

It appears that he did not have an appropriately sized circlip and so instead pressed a washer in its place, hoping it would do the job. Which it did.

I tried tapping it in, but it wouldn't budge. I drilled a few holes around the perimeter and pried it out with a dental tool and a pair of needle nose pliers. No circlip underneath but the groove is there. :

Where he found an aluminum washer the exact diameter, both inner and outer, to do this job, I'll never know.

I know I'm putting it back together with a circlip, damnit!

And oh, the internals were perfect and totally clean so I didn't need to tear it apart after all. :-\

Whatever. I'm over it. Painting all the brake stuff tomorrow!

-Deek