Front Master Cylinder

[Crankthat]

Not sure on size of hole but.

For cutting torches they make a tool to clean nozzles.

It is a very,very small drill bit that affixes to a pen like holder to drill out by hand.

Should be small enough to clean your gunk, as the cutting torches have several small holes in the tip.

[G. Bruns]

Dogma, have you actually drilled out the hole and had the brakes stop functioning? Just because something has been designed by engineers and executed by machinists doesn't mean there isn't a better way to do something.

[Octain]

Get it disassembled and soak it in carb dip. Works great.

[Crankthat]

Get it disassembled and soak it in carb dip. Works great.

Sounds like a winner!

Oh yeah in my earlier post I just meant use torch drill bit to drill out gunk, not ID of hole.

[natejelovich]

Thanks all for the replies!

I ended up getting it, after lots of rounds of brake cleaner and the dentist pick (not sure the actual name...). I finally ended up tapping it with a hammer and it cleared out.

I put everything back together and started working the brakes. It was good news to see the bubbles come up when I would grab the lever, however, after sometime, the bubbles stopped... is that normal?

I drained the fluid and am going to give it another shot tonight to see if I can't get it to work. It was building up some pressure, but not enough...

[Bass Man]

I rebuilt my MC this summer, and the dust boot held the piston in pretty well untill I got all of the bits out. I like to use BBQ skewers to scrape crud off of parts; nicely pointed end for small holes, blunt end for the big chunks, they wont gouge the surface, and PB blaster gives a great flavor to steak tips when you're done working on the bike!

I agree with Dogma, there is a reason for that hole to be that size; much easier to manufacture if bigger. Stared at the cross-section for a while as suggested before becoming a believer, think I might have seen Elvis in there...

Cheers!

[oldrookie]

Bubbles are a sign that there is air in the system. They should stop after you "bleed" the system. If they don't, you have a leak. I've spent all summer trying to get my rebuilt MC to work correctly.

Putting a new used one on today if the replacement sight glass gets here in the mail.

[natejelovich]

I think you and I are in the same boat... I've spent all summer working on my brakes and master cylinder...

Right now, I've narrowed it down to a "leak" coming from the brake lever end... something isn't sealing correctly. So, when I grab the lever to build pressure, air seems to be coming in from the lever end.

The real bummer thing about this is that there is no master cylinder rebuild kit that I've been able to find for my bike. It's too old I guess...

[daturat100r]

I think you and I are in the same boat... I've spent all summer working on my brakes and master cylinder...

Right now, I've narrowed it down to a "leak" coming from the brake lever end... something isn't sealing correctly. So, when I grab the lever to build pressure, air seems to be coming in from the lever end.

The real bummer thing about this is that there is no master cylinder rebuild kit that I've been able to find for my bike. It's too old I guess...

Same problem here on my 750LN and just ordered kit thru suzuki today.NZ$106 in sales tax no problem just a wait to come from japan

[oldrookie]

Isn't this the part you need? Listed as PISTON/CUP SET
59600-45811 (replaces 59600-31827) 1 $44.78 $33.59

at http://www.boulevardsuzuki.com/fiche...1979&fveh=2141

I think you and I are in the same boat... I've spent all summer working on my brakes and master cylinder...

Right now, I've narrowed it down to a "leak" coming from the brake lever end... something isn't sealing correctly. So, when I grab the lever to build pressure, air seems to be coming in from the lever end.

The real bummer thing about this is that there is no master cylinder rebuild kit that I've been able to find for my bike. It's too old I guess...

[natejelovich]

Thanks!

That's what I'm trying to figure out. I emailed them to see if that includes everything I need , or if it's just the piston. I mainly (I think) need the rubber o-ring that surrounds the piston, and the dust boot. I pretty much have everything else. But if it's the entire set (all washers, snap ring, spring, etc.) that's even better.

So, just waiting for a reply. From either them, or Z1.

And I should say, it looks like it includes everything (from the diagram) but at this point, and after this long, I'm kind of ready to be safe than sorry and order something that's not exactly what I need.