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reservoir removal/replacement

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    #1

    reservoir removal/replacement

    I did a quick search but could not find anything similar

    I have this style break reservoir on my GS400 but i need to remove it so i can replace it with a rebuild kit and also paint the handle section to cover the years of chipped paint.

    Once the cap is removed and the screws are out is there a trick to poping the plastic reservoir out? It looks like it should just pop out with enough force but i dont want to damage it.

    Error Page | eBay
    http://www.ebay.com/itm/suzuki-gs1000-gs850-gs750-gs450-gn400-gs-MASTER-CYLINDER-RESERVOIR-CUP-CAP-KIT-/390541346031
    Tags: None
    #2
    yep it should just pop out, use a small thin screwdriver to try and prise it off, maybe a fe LIGHT taps with a hammer. it is just stuck on with years of crud
    1978 GS1085.

    Just remember, an opinion without 3.14 is just an onion!

    Comment

      #3
      Yup just pops out, get a good grip on with you strong hand and wiggle just a bit and out it comes. When you install the new one, make sure you lube it just bit and it will pop back in.
      sigpicMrBill Been a GSR member on and off since April 2002
      1980 GS 750E Bought new in Feb of 1980
      2015 CAN AM RTS


      Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

      Comment

        #4
        Be gentle!

        When I first got my 450 I attempted that and could not get it to budge so I just flushed the system as it was.

        During the rebuild, I tried again, and it had gotten so hard and brittle that levering in any direction just started cracking it.

        Turned out that a PO had let brake fluid run down the outside and it seeped in between the reservoir and base, which over time almost melted them together...
        1982 GS450E - The Wee Beastie
        1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

        sigpic

        450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

        Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

        Comment

          #5
          Originally posted by pete View Post
          Be gentle!

          When I first got my 450 I attempted that and could not get it to budge so I just flushed the system as it was.

          During the rebuild, I tried again, and it had gotten so hard and brittle that levering in any direction just started cracking it.

          Turned out that a PO had let brake fluid run down the outside and it seeped in between the reservoir and base, which over time almost melted them together...
          Yikes. I dont think thats my issue I can spin it pretty freely it just wont pop out

          Comment

            #6
            Originally posted by GS(X)400 View Post
            Yikes. I dont think thats my issue I can spin it pretty freely it just wont pop out
            It will pop out, with the oring it sits in there pretty tight. Might need a screwdriver to get it started. Mine was in there for 31 years before I replaced it and it come out just fine.
            sigpicMrBill Been a GSR member on and off since April 2002
            1980 GS 750E Bought new in Feb of 1980
            2015 CAN AM RTS


            Stuff I've done to my bike:dancing: 1100E front end with new Sonic springs, 1100E swing arm conversion with new Progressive shocks installed, 530 sprockets/chain conversion, new SS brake lines, new brake pads. New SS fasteners through out. Rebuilt carbs, new EBC clutch springs and horn installed. New paint. Motor runs strong.

            Comment

              #7
              If it's spinning freely, then just wiggle it out as you spin it, should come out with some gently prying.
              1982 GS450E - The Wee Beastie
              1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

              sigpic

              450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

              Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

              Comment

                #8
                Originally posted by pete View Post
                If it's spinning freely, then just wiggle it out as you spin it, should come out with some gently prying.
                Screw driver did the trick lol

                Comment

                  #9
                  Excellent!
                  1982 GS450E - The Wee Beastie
                  1984 GSX750S Katana 7/11 - Kit Kat - BOTM May 2020

                  sigpic

                  450 Refresh thread: https://www.thegsresources.com/_foru...-GS450-Refresh

                  Katana 7/11 thread: http://www.thegsresources.com/_forum...84-Katana-7-11

                  Comment

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