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Discussion Starter #1
Not dead yet but...

Two of the four screws on the top side of the front brake reservoir broke off (2000 KLT). The threaded remains are still in the casing. I am going to attempt the "easy out" method. Otherwise...

I may need to replace the entire unit...ouch!

Before I damage or destroy anything further, any suggestions, ideas,condolences?

Gratefully,

Kimble
Phoenix
 

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Well if you can break the other two off you can pull the lid, and it may give you enough threads to get on with small vise grips.

I would soak the two remaining in penetrating oil and try. If they snap then I would dab all them with a q-tip and penetrating oil a bunch of times, and then go after them.

Now you are doing Lefty Lucy and all that, right? :D
 

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I did the same (not really) thing. I stripped the hex right off the screw. I had great success with the sears "easy out bits" you need a very little bite to get them out...Good luck! :D

KJN said:
Not dead yet but...

Two of the four screws on the top side of the front brake reservoir broke off (2000 KLT). The threaded remains are still in the casing. I am going to attempt the "easy out" method. Otherwise...

I may need to replace the entire unit...ouch!

Before I damage or destroy anything further, any suggestions, ideas,condolences?

Gratefully,

Kimble
Phoenix
 

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Registered
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99 Posts
Discussion Starter #4
Thanks to all.

This is the first time the cap has been off since I owned her. (18 months). I think the screws were over tightened or may never have been out.

Just in case,,,I've found a couple of used assemblies on Ebay.

Thanks for all the suggestions...

Kimble
Phoenix
 

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I bought those TV easy outs, saw them also in mall the as seen on tv store.
The smallest one looks small.
Just took all four of my screws off and though they would strip, hard downward pressure and good sharp screwdriver is key.

Would like 4 new screws to replace mine.
Also anti-seize is prob a good idea.
Brake fluid attracts moisture so that makes these suck.
 

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About to replace my front brake master on my 2000 lt
How many screws hold it to the handlebars?
cannot find any details on how to remove it
 

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I bought those TV easy outs, saw them also in mall the as seen on tv store.
The smallest one looks small.
Just took all four of my screws off and though they would strip, hard downward pressure and good sharp screwdriver is key.

Would like 4 new screws to replace mine.
Also anti-seize is prob a good idea.
Brake fluid attracts moisture so that makes these suck.
Another great product is "Screw Grab". http://www.screwgrab.com/

Watch the video.

Robert
 

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So I finished the Front Master rebuild(replaced piston and seals from beamerboneyard.com)

So lessons learned, Throttle grip, does not need to be removed
Only right side handlebar cover needs to come off
Need long skinny Cir-clip pliers, just barely was able to use sears 13 dollar.

So here is the procedure as I know it now
Take off any screws holding the right side perch together.
Remove right side lever pivot.
Put drop cloth on bike to protect from fluid spill.
Drain reservoir into small container by loosening perch clamp screw.
Then loosen the bolt on brake line.
After all fluid is gone, remove cir clip that retains the piston.
Then make sure cylinder is clean.
Wet new piston with dot 4 fluid.
Install new piston.
Trick I used was screwdriver through circlip holding piston in, then I strapped screwdriver handle to right grip.
While it was there I was able to get circlip into slot, tab faces down.

Then reconnected and bled hose union.
Then bled both calipers twice, still no pressure.
Then Bled ABS front circuit, got pressure.
Then went back and bled calipers again, then abs again.

Full pressure now.

Not sure I ever had full pressure before.

In restrospect, master may not have died, could have just been air in ABS unit migrated after riding.

Still have abs lights flashing back and forth.
 

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By the way, master screws on mine are brass, very soft!

Thanks to all.

This is the first time the cap has been off since I owned her. (18 months). I think the screws were over tightened or may never have been out.

Just in case,,,I've found a couple of used assemblies on Ebay.

Thanks for all the suggestions...

Kimble
Phoenix
 
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