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    #1

    Front brake master cyclinder

    I got the piston in the front brake master cylinder to move, and I can hear air moving through the hole where the brake hose goes. However, when I hooked it to the hose, filled it with fluid and pumped the handle, nothing came out. A few air bubbles come up. I took the screw out and pumped the handle again, but no fluid came out of the hole.

    I have not been able to remove the piston.
    1980 GS550E
    Tags: None
    #2
    Oh, man!

    That is going to be an adventure for you!

    I ended up gouging the piston and just bought a new one. Begins on Post #56:

    82GS750T - Seal, T/M Gear Shift Oil - The GSResources Forums
    https://www.thegsresources.com/_forum/showthread.php?216696-82GS750T-Seal-T-M-Gear-Shift-Oil/page2
    Place your 4 cylinder GS engine, drivetrain or clutch related questions in this forum.




    Got them pretty clean!


    Ed
    GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
    GS750TZ Parts Bike [Seq#6036]
    GSX-R750Y (Sold)

    my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

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      #3
      Here it is with the circlip, washer, and gasket removed. I haven't been able to get the piston out.15786190122846623654847335597287.jpg
      1980 GS550E

      Comment

        #4
        Ohhhhhhh!

        That was tough to get out!

        I have pic of that too! There's a special tool to pinch the circlip out. And I think I used a needle-nose to pull the piston out. Be careful not to scratch the cylinder walls.



        Ed
        Last edited by GSXR7ED; 01-09-2020, 10:33 PM.
        GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
        GS750TZ Parts Bike [Seq#6036]
        GSX-R750Y (Sold)

        my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

        Comment

          #5
          That's the thing... the piston won't come out.
          1980 GS550E

          Comment

            #6
            Keep your patience. Gently keep gripping it with pliers...it does loosen up...but the rubber is suctioning it.

            It will eventually come out.

            Ed
            GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
            GS750TZ Parts Bike [Seq#6036]
            GSX-R750Y (Sold)

            my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

            Comment

              #7
              Originally posted by GSXR7ED View Post
              Keep your patience. Gently keep gripping it with pliers...it does loosen up...but the rubber is suctioning it.

              It will eventually come out.

              Ed
              It sounds like there's a piece of metal inside stopping it from coming out. Did Suzuki make master cylinders that couldn't be opened?
              1980 GS550E

              Comment

                #8
                Here's me trying to remove the piston.

                Brake Master Cylinder
                https://vimeo.com/383925309
                This is "Brake Master Cylinder" by Jasper Adkins on Vimeo, the home for high quality videos and the people who love them.
                1980 GS550E

                Comment

                  #9
                  Originally posted by ZombiePotatoSalad View Post
                  It sounds like there's a piece of metal inside stopping it from coming out. Did Suzuki make master cylinders that couldn't be opened?
                  That piece of rubber around the Piston is part of the problem...it's suctioning the Piston from being removed.

                  I kept at it for a couple of days while the other pieces were soaking in solvent. Eventually, it popped out.

                  I had to learn patience. Just keep gently pulling at it...you are dislodging it gradually.

                  Ed
                  GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
                  GS750TZ Parts Bike [Seq#6036]
                  GSX-R750Y (Sold)

                  my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

                  Comment

                    #10
                    Is the circlip removed? Take a dental pick and pull the rubber boot out (you can get a new one)
                    Cowboy Up or Quit. - Run Free Lou and Rest in Peace

                    1981 GS550T - My First
                    1981 GS550L - My Eldest Daughter's - Now Sold
                    2007 GSF1250SA Bandit - My touring bike

                    Sit tall in the saddle Hold your head up high
                    Keep your eyes fixed where the trail meets the sky and live like you ain't afraid to die
                    and don't be scared, just enjoy your ride - Chris Ledoux, "The Ride"

                    Comment

                      #11
                      Originally posted by cowboyup3371 View Post
                      Is the circlip removed? Take a dental pick and pull the rubber boot out (you can get a new one)
                      The circlip is removed...he's having issues pulling the Piston out.

                      It's wedged in there tight because the rubber seal around the Piston must travel upward and out of the chamber.

                      It takes time because of the suction the rubber is causing because it's been in there (probably) since the bike was built.

                      Ed
                      GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
                      GS750TZ Parts Bike [Seq#6036]
                      GSX-R750Y (Sold)

                      my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

                      Comment

                        #12
                        might try removing the the reservoir and getting some penetrating oil (PB blaster?) in at it through the holes in there. Also let some PB sit on top of the plunger for a couple of days.
                        Rich
                        1982 GS 750TZ
                        2015 Triumph Tiger 1200
                        BikeCliff's / Charging System Sorted / Posting Pics
                        Destroy-Rebuild 750T/ Destroy-Rebuild part deux

                        Comment

                          #13
                          Originally posted by Rich82GS750TZ View Post
                          might try removing the the reservoir and getting some penetrating oil (PB blaster?) in at it through the holes in there. Also let some PB sit on top of the plunger for a couple of days.
                          I just watched the video OP posted and yes! The reservoir cap/lid needs to come off to let air flow through those tiny vents in the Master Cylinder.

                          Good call!

                          Ed
                          GS750TZ V&H/4-1, Progressive Shocks, Rebuilt MC/braided line, Tarozzi Stabilizer[Seq#2312]
                          GS750TZ Parts Bike [Seq#6036]
                          GSX-R750Y (Sold)

                          my opinion shouldn't be taken as gospel or in any way that would lead you to believe otherwise (30Sep2021)

                          Comment

                            #14
                            Is it a concourse build? If not forget it & put one on from an EX650... Actually yours is probably single brake so look at the 250 or the KLR
                            1980 GS1000G - Sold
                            1978 GS1000E - Finished!
                            1980 GS550E - Fixed & given to a friend
                            1983 GS750ES Special - Sold
                            2009 KLR 650 - Sold - gone to TX!
                            1982 GS1100G - Rebuilt and finished. - Sold
                            2009 TE610 - Dual Sporting around dreaming of Dakar..... - FOR SALE!

                            www.parasiticsanalytics.com

                            TWINPOT BRAKE UPGRADE LINKY: http://www.thegsresources.com/_forum...e-on-78-Skunk/

                            Comment

                              #15
                              Originally posted by salty_monk View Post
                              Is it a concourse build? If not forget it & put one on from an EX650... Actually yours is probably single brake so look at the 250 or the KLR
                              A what? What's a concourse build?
                              1980 GS550E

                              Comment

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