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09-28-2008, 6:17 PM troutwing Joined on 09-28-2008 Posts 1 Master cylinder reservoir removal     Has anyone had to remove the opaque, rectangular reservoir on their master cylinder?     I bought an '82 GL500I Silverwing. Only real problem was the front brakes were locked up. I tried to clear the three holes in the bottom of the reservoir, as many of you had posted, but had no luck.   When screwing the cover back on, both screws tightened prematurely, then suprisingly snapped with little effort.(weakened by electrolysis?)  If it's possible to fix those screws, I need to remove the reservoir   So... is it just a tight fit on the reservoir that will require some careful prying, because I tried to pull straight up with some light twisting, and it didn't budge.  I thought I'd ask before I break anything else.   thanks for your help,     Mike        Report

09-28-2008, 6:47 PM RichNCT Joined on 03-02-2006 Connecticut, USA Posts 3,459 Re: Master cylinder reservoir removal Yes, it's just a pull out, but the o-ring seal is stiff.  I have used a pair of flat screwdrivers and pried as evenly as possible and not cracked the reservior, done it a couple of times (different bikes).  The ring on the bottom of the reservoir has a sort of OD barbed edge which engages the o-ring. Refueling on The James Bay Road, 2009 Born to be relatively wild (for a grampa x 3) GL650I, CX650E, CX650T    Report

10-11-2008, 12:51 PM Dash Joined on 08-25-2008 San Francisco, California Posts 628 Re: Master cylinder reservoir removal I had the exact problem with my '82 CX500 and solved it by rebuilding the front brake caliper.  Kit cost $22 at local cycle shop and was super easy.  Just take apart the caliper, clean everything thoroughly and put it all back together using the new seals. My plastic master cylinder reservoir was difficult to remove but careful prying straight up with 2 screwdrivers finally popped it off.  There is no hidden lock holding the plastic reservoir on but just an old stiff o-ring.  I also had a broken screw and thus, had to drill it out and retap the hole in the die-cast body.  There's not much metal there so be careful if you have to do this.  If you have a stub of broken screw that you can grab with vice-grips, try heating the broken screw shaft with a torch and then cooling it by spraying with WD-40.  Repeat this procedure several times and then try the pliers.  Be sure to take out the piston BEFORE applying heat.  Regular snap ring pliers is the only tool needed for this. Good luck. '82 CX500 '81 GL500 '76 GL1000 Goldwing '75 Suzuki GT250 '70 Moto Guzzi Ambassador '67 Honda Dream '67 Honda Dream '70 Moto Guzzi Ambassador '75 Suzuki GT250 '76 Goldwing '81 GL500 Silverwing '82 GL500 Silverwing <--just bought it 16 Mar 2010 '90 Yamaha XT350 '91 Kawasaki KDX200    Report

Honda CX500 & G... » CX500 GL500 Tra... » Technical Help ... » Master cylinder reservoir removal

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