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Front Master Plunger Removal?

  • Thread starter Thread starter gs1000emt
  • Start date Start date
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gs1000emt

Guest
Well I ordered $108 worth of front brake rebuild parts for my bike the other day. They will be here shortly so I started the disassemble of the master cylinder? How do you remove the plunger? I searched but could not come up with anything.
 
there should be an internal circlip in there. probably hidden by rust and crud. pop that out and the plunger should pull right out
 
chuck hahn said:
You will need straight LONG pins to get into the circlip.
Click to expand...

In particular, these:

DSC05783.jpg


I modified some HF needle-nose pliers on the bench grinder, but the one in the pic looks easier to use.

Tear out the rubber boot, and there may be a plastic ring left over from that. After that, keep digging. It IS in there.
 
well I tore the boot off and eventually pulled the plastic ring out. Then I got to the C Clip and got it out. But I still cannot remove the plunger. I tried to twist and pull but nothing. Is anything else holding this in? Is is threaded?
 
no its not threaded, probably just stuck in with corrosion. soak in some wd40 or similar over night, then try again. a bit of heat may help as well
 
No threading, it's just stuck.

You can soak it, heat it and try again.
Or you can drive a wood screw into the head of the plunger and yank it out with pliers.
 
gs1000emt said:
well I tore the boot off and eventually pulled the plastic ring out. Then I got to the C Clip and got it out. But I still cannot remove the plunger. I tried to twist and pull but nothing. Is anything else holding this in? Is is threaded?
Click to expand...

Mine had a c-ring, plastic ring and then the circlip. And yep it should pop right out. Prolly more crud needs removing.
 
ok i"ll give that a shot. The plunger moves back and forth freely but will not advance out while pulling on it. Cleaned it up and hit with air but it doesnt look like any other cclips are holding it in.
 
Good day or 2 soak in extra strength white vinegar will eat the rust up and not damage the paint.
 
1_v8_merc said:
No threading, it's just stuck.

You can soak it, heat it and try again.
Or you can drive a wood screw into the head of the plunger and yank it out with pliers.
Click to expand...

I tried everything on mine and this is the only way it came out.
 
Last edited:
Ok....after several rounds of penetrating lube I was able to get the plunger out by putting the MC in a vice and smacking the plunger with a screwdriver and dead blow hammer. After I got it out I cleaned it up as much as possible and put it in the carb/parts cleaner pail for about 2 hours. Pulled it out and washed it with soapy water and blew it out with compressed air. Looks much better than before. I have 2 questions though....First is I know I need to make sure that very small weep hole is clear. There are 2 the same size and one is clear and the other is not. Does only one of the holes actually go through to the plunger? Also Im gonna hit it with some new black paint (rattle can). Should I use VHT satin black?
 
gs1000emt said:
Ok....after several rounds of penetrating lube I was able to get the plunger out by putting the MC in a vice and smacking the plunger with a screwdriver and dead blow hammer. After I got it out I cleaned it up as much as possible and put it in the carb/parts cleaner pail for about 2 hours. Pulled it out and washed it with soapy water and blew it out with compressed air. Looks much better than before. I have 2 questions though....First is I know I need to make sure that very small weep hole is clear. There are 2 the same size and one is clear and the other is not. Does only one of the holes actually go through to the plunger? Also Im gonna hit it with some new black paint (rattle can). Should I use VHT satin black?
Click to expand...

At first the two holes look the same. One goes through, one stops short. In the bottom of the shallow hole is a tiny hole that you may not be able to see until it's cleared. Carb dip not clear mine. Keep at it with cleaner and a stiff piece of wire, like from a brush.

I used whatever black paint I had on hand. So long as I keep brake fluid off of it, it's fine.
 
Ok so i do have to clear that second hole too. I'll hit it with some cleaner and try to get a piece of wire brush through there. Thanks
 
Tech73 said:
I tried everything on mine and this is the only way it came out.
Click to expand...

Yep. I don't even waste my time with penetrating fluid. I just drill it, cut it, torch it or whatever it takes. I have too many projects for patience, lol.
 
Still cant get through that little pin hole. I cut a piece off my wire brush and dug, soaked in parts cleaner, hit with carb cleaner, dug more, blew out with air compressor but still cannot get through that little hole. Any other ideas?
 
If you dont have the tool..... I removed my circlip with some small hemostats. It took a few tries, but it worked.

The repair kit parts I bought from PowerSportsPlus.com had the wrong sized plunger and circlip, and they have been unresponsive in getting me the right kit.

My old plunger looked OK, So I put everything back together using the old plunger and circlip.

Now the brake wont stiffen up and air swishes into the reservoir when pumping the brake.
 
Gregory said:
The repair kit parts I bought from PowerSportsPlus.com had the wrong sized plunger and circlip, and they have been unresponsive in getting me the right kit. .
Click to expand...


Update on PowersportsPlus.com. It took a while but they fianlly made it right.

After sending this post to them they did contact me back and took care of getting me the new part... and although they said they dont have the ability to send me the confirmation reciept (i hope) reimbursing me for the return part.
 
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