reservoir removal/replacement

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  • GS(X)400
    • Feb 2026
    #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.

    Pardon Our Interruption...
    http://www.ebay.com/itm/suzuki-gs1000-gs850-gs750-gs450-gn400-gs-MASTER-CYLINDER-RESERVOIR-CUP-CAP-KIT-/390541346031
    Tags: None
    • Agemax
      Forum Guru
      • Apr 2008
      • 8371
      • plymouth uk
      #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

        • Guest
          #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.

            Comment

            • Guest
              #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...

                Comment

                • GS(X)400
                  #5
                  Originally posted by pete
                  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

                    • Guest
                      #6
                      Originally posted by GS(X)400
                      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.

                        Comment

                        • Guest
                          #7
                          If it's spinning freely, then just wiggle it out as you spin it, should come out with some gently prying.

                            Comment

                            • GS(X)400
                              #8
                              Originally posted by pete
                              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

                                • Guest
                                  #9
                                  Excellent!

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