master cylinder rebuild - seeking identification/advice

[Guest]

Greetings all,

It's time to rebuild the m/c in my stock 1980 GS400E (and in one belonging to my buddy too).

I have to order parts and i am not sure exactly which kit will fit.
This looks like what i want: part#59600-45841, but how to be sure?
Here are some photos from my caliper rebuild:

http://www.flickr.com/photos/75842363@N00/sets/72157624021144423/

you - "why didn't you do the m/c when you replaced the line Jagir?"
me - "duh....."

I really do not want to deal with the hassle of returning it if it arrives and is the wrong piece. How about opinions regarding original Suzuki parts ($50ish) vs aftermarket ($30ish)? It's brakes so price doesn't matter, but if I can save some cash, I can lubricate my throat with beer while I work.

Furthermore, I do not want to tear my m/c apart (for reference) until it's time to do the overhaul. I'm still sneaking in some rides here and there so I do not want to disable the bike and I don't want to deal with brake fluid clean-up more than once.

Also, I figured that there are probably a hundred or more people on here who could identify it instantly, provide me with a link to the part, probably for the best price and most likely with some other great piece of advice.

If it matters, I am looking for two of these kits and one newish reservoir (because I will be working on two of these bikes)

Thanks in advance

[Steve]

Can't help you with your selection, but I do feel the need to comment on an observation.

You said "It's brakes so price doesn't matter", so I get the impression that you feel that brakes are rather important.

Then you said "... I can lubricate my throat with beer while I work." Even if I drank, I would hold off "lubricating the throat" until after the brake work is done.


One more suggestion, while you have the master cylinder apart, ... make sure you clean out that tiny little bleed hole in the bottom of the reservoir. That has been plugging up on several of the newcomers who have tried cleaning their brakes and did not know about that hole. If you don't clean it, you will only get a couple of miles down the road and the brakes will lock up on you. Usually slowly enough that it won't put you down, but you will not be able to move the bike.

.

[cowboyup3371]

Jagir, this is that little voice in the back of your head. Listen to him about the cleaning part as I'm one of those unlucky newcomers that didn't clean it very well. I got about 4 days of riding - over 150 miles and mine did exactly that.

[Jagir]

points taken.

will clean the tiny hole with one bristle from a wire brush and celebrate after.

[Texasgs]

re

points taken.

will clean the tiny hole with one bristle from a wire brush and celebrate after.

The put it in the dishwasher after you open up the passage, and otherwise clean it, and it will be ready to build. It works pretty good. You can lubricate your throat during the rinse cycle.

[Jagir]

Can't help you with your selection, but I do feel the need to comment on an observation.

You said "It's brakes so price doesn't matter", so I get the impression that you feel that brakes are rather important.

Then you said "... I can lubricate my throat with beer while I work." Even if I drank, I would hold off "lubricating the throat" until after the brake work is done.


One more suggestion, while you have the master cylinder apart, ... make sure you clean out that tiny little bleed hole in the bottom of the reservoir. That has been plugging up on several of the newcomers who have tried cleaning their brakes and did not know about that hole. If you don't clean it, you will only get a couple of miles down the road and the brakes will lock up on you. Usually slowly enough that it won't put you down, but you will not be able to move the bike.

.

Do you mean this little bleed hole? Looks much bigger than a one wire bristle.
(Photo is taken with a light shining down the cylinder)

[Jagir]

here's a photo of the mess in there

The rubber boot that keeps it clean in there was a little bit busted up at the bottom. It seems that the rubber was compromised and the metal inside the rubber boot at the bottom rusted a bit. The oxidation seems to have spread down the shaft of the piston.

It's taken a while, but I'm glad I am fixing this all up.

[cowboyup3371]

You will want to clean that reservoir up some more because I think the return hole is in the 1130 - 12 o'clock position from the way I'm reading the picture. If you don't, the brakes will lock up and you won't go very far very fast (if you stay upright).

Ask me how I know.

[Steve]

Do you mean this little bleed hole? Looks much bigger than a one wire bristle.
(Photo is taken with a light shining down the cylinder)

No, the "tiny little hole" (otherwise known as "that bloody hole") is located under the plastic tab at the 9 o'clock position.

The best way to access it is to remove the reservoir. Simply pry it straight up with a screwdriver.

While the reservoir is off, remove the o-ring that seals it, clean the groove in which it lives.

When all is clean, lube the o-ring with fresh brake fluid, snap the reservoir back into place.

By the way, I get my rebuild kits from Parts-n-More. I also just got a new reservoir kit, which includes reservoir, o-ring, diaphragm, cap and bolts.

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