Topic: MAster cylinder circlip woes...

[amattel]

I have bought 3 different circlip pliers including the one from sears
mentioned on this site.

I am having a hard time trying to get the circlip out of the front brake
master cylinder on my cb750k2....

I am getting frustrated...  The last pliers I ordered arrived today... but
they have one side that has a bigger post than the other so I can only catch
one side of the circlip...

I have just tried grinding the sears tool so it will fit all the way into
the cavity where the circlip resides, but it is hard to see in there and at
the same time have a screwdriver jamming the piston down out of the way AND
fiitting the circlip pliers in as well...  (what was honda thinking!?!?)

It seems like it should be an easy job other than this circlip thing...

IF this is my original 33 year old master cylinder is it possible the circlip has become one with the cylinder wall?

Adam

[Teach]

I had the same problems with mine...I believe they're all this way.  I really can't remember how I got it out.  I only used a set of straight circlip pliers and a flathead screwdriver.  Pried it out somehow, trashing the clip.  All I can tell you is keep at it...it'll come out eventually.

[Bob Wessner]

is it possible the circlip has become one with the cylinder wall?

Could be, sort of. The clip is steel, the cylinder aluminum and dissimilar metals can set-up a corrosion barrier. Do you detect any movement at all in any part of the clip when you wrestle with it? Dry soaking some penetrating oil in there overnight and tap around as best you can with a screw driver, then give it another try. Not sure which Sears pliers you used, but the ones I used were a tight fit, but they worked.

[amattel]

Is it any easier to get the new one in?

Did prying it out damage the cylinder?

thanks

Adam

[Bodain]

Hee hee... When it was time to rebuild my master cylinder. I went out and purchased the tool to get the circlip out.

Eventually I tossed the tool in the corner of the garage. Mission accomplished with a pointy tool and screwdriver.

[damn_yankee]

I had to grind down one side of my circlip pliers to fit in the recess before I was able to remove the clip.
Getting it back in is even harder if I remember correctly!
You should be able to rotate the clip in the slot with a long thin awl or other tool to see if it is seized in there.

[Bob Wessner]

[Is it any easier to get the new one in

Yes. Besides, you will be delirious when you get that far.  

Just kidding, but yes, it is easier to install.

[MRieck]

These are what you need.

[amattel]

These are what you need.

I wish the three pliers I bought weren't scratched up and were returnable so I could get a better tool like these three beauties *LOL*

I have to remember the lessons I learned from "Zen and the art of motorcycle maintenance"...  When I get frustrated it is time to do something else.. Darn it all!

[hymodyne]

I found a pair of long jawed needle nose pliers, thinner profile than regular ones-thin enough to be able to move when manipulating the clip. I then took a fine file and eliminated the taper at the tip, leaving a pair of points that could be pushed down into the clip, compressed, and capable of pulling a circlip at least out enough to get a pic or something else under it. they made installation easier too.

hym

[jotor]

Mission accomplished with a pointy tool and screwdriver.

I use two pointy tools made from old small phillips screwdrivers--about 4" long.  All the sealing is beyond the circlip so a bit of minor damage doesn't matter.  (It's a Honda--not a BMW, after all!)

Joe

[paulages]

after an hour of cursing every time i have done this (it doesn't get any easier) even with a proper set of circlip pliers, i have managed to get one side up, then used a pointy tool to run around it, like removing a tire.

[techy5025]

On my K0 master cylinder, you can hold the piston down by runnin a round screwdriver
through the hole where the mirror mounts.  That will help.  An icepick (remember them  )
and a thin screwdriver can then be used to prize the clip up and out...sorta like
removing a tire.  I was never able to find circlip pliiers that worked.

A vice to hold the assembly helps also.  I have plenty of vices...no problem there!

Jim

[amattel]

Done!  Thank you very much.

I ordered my third set of circlip pliers... with which I was STILL NOT ABLE to just sticl the pointy parts in the holes and take it out.

I was able to get ONE of the points of hte new pliers in a hole and pried up and BROKE OFF one of the ends of the circlip 

The good part was after it broke the boot retaining ring which I suspected was stcuk down there was sticking up enough to grab with a hemostat (and then I could see the holes more clearly)

I then went to Kragen and found slightly angled pick type tool for $5

with this I was able to hook the other hole and coax the circlip out. YES!

So now the job is done and I rode up to The Wall here in Berkeley.  Nice sunset and lots of bikes.  I am get to ride again!!!

Thank you all for sharing.  It seems my experience was normal for these bikes.

Adam

[Noel]

Just wanted to share my, um, enlightening experience.

First time rebuilding a master cylinder and, God willing, last.

Had the same experiences getting the circlip out. Lots of fun.

The enlightenment part came when I was prying on the thing and it occured to me that safety glasses might be a good idea. Put 'em on and 30 seconds later the circlip came out, followed immediately by the boot retaining clip which achieved Mach 3 on the way out and nailed my glasses directly over my pupil. My blink occured so long after the actual event that I actually laughed at myself.

First time I've genuinely needed to have been wearing glasses. And I can't express how glad I am to have been.

End of sermon. 

[Bob Wessner]

V-e-r-y good point! Glad your "the little voice" spoke to you before you started the job. 

[Noel]

Oh yeah, me too!

I'm usually not one to put up this kind of cautionary tale, especially not to a bunch of guys who 1) probably have a whole heck of lot more experience than me, and 2) think "fun" is doing the ton on thirty year old motorcycles they fixed themselves with wire and vice grips, ie. probably not interested in some sissyboy telling them to wash behind their ears and always wear a rubber.

But I'll tell you, it was an odd emotion running through me last night. A mixture of cold fear over what I almost did to myself mixed with a wonderful gladness at having, for once, done the right thing and been rewarded for it.

If nothing else, I don't think I'll be leaving the glasses on the workbench while I work on my bike any more.

[Bob Wessner]

It's really easy to become complacent whether you are working on them or riding them. Comfortable is one thing, complacent is another entirely and bad in my book. Little reminders are always welcome.

[my78k]

I think the Circlip Pliers are HIGHLY over rated! Still have had no success with them...what I did have success with was very small hex keys...they were small enough that they fit in the little hole and I just sort of compressed them...then did the "tire" trick.

As for the safety lecture...couldn't agree more...I'm not normally one to preach it but have had similar situations. I actually spent 15 bucks on a good pair of safety glasses that not only worked but fit well and actually don't look half bad...that way I didn't have any excuse anymore not to wear them...after all ever try riding with only one eye? Having no depth perception could be detrimental to your riding career...


Dennis

[malcolmgb]

just completed my Master Cylinder rebuild. The circlip pliers I used were perfect for the job

http://www.machinemart.co.uk/product.asp?p=040210064&r=2077&g=111

this is of course in the UK so not sure it is of help elsewhere. I was on the verge of getting my daughter to go to Sears for me and ship them over to me.

[phylo101]

Um, REALLY stupid question....is the piston leaking? Does it move in and out without moving? If the answers are NO and YES, then why are you replacing? Ive never yet come across a Four mastercylinder that actually NEEDS this done unless its been leaking. ALL the brake issues are elsewhere in the system.

phlo

[amattel]

Um, REALLY stupid question....is the piston leaking? Does it move in and out without moving? If the answers are NO and YES, then why are you replacing? Ive never yet come across a Four mastercylinder that actually NEEDS this done unless its been leaking. ALL the brake issues are elsewhere in the system.

phlo

Mine was leaking.  I certainly didn't wrestle with that circlip just for the fun of it!

Adam

[rob]

I had a tough time getting mine off too,  I found it worked well to twist the circlip around to loosten it up, then use the pliers, and having a really good light source works wonders.

I have this pair from Canadian tire, Mastercraft Snap-Ring Pliers Set, Product# 58-4622-0

http://www.canadiantire.ca/assortments/product_detail.jsp?FOLDER%3C%3Efolder_id=1408474396669777&PRODUCT%3C%3Eprd_id=845524441900007&ASSORTMENT%3C%3East_id=1408474396670271&bmUID=1144285510606&assortment=primary&fromSearch=true

URL may or may not work, looks like it has some session stuff in it.

The good news, once its out its easier to put in! good luck!

Rob

[my78k]

Was definitely leaking...the rubber seal was ripped...PO musta done something...

[techy5025]

I'm glad this post was revisited as I am getting ready to do this again.
I have found that coaxing the clip around to where one hole is next
to the cutout for the lever and then just prizing it out with a thin pointed
screwdriver works best for me.

Who cares if the clip is warped.....a new one is going in anyway. 

Jim