Removal and installation of reservoir.

After the cap and diaphragm are removed (lid assy) you will want to determine how the reservoir body
will be removed. Now keep in mind we are using a '83 Honda GL1100 master cylinder as an example.
Not all reservoirs come off the same as this one and some are simply part of the body. Some units will
have internal screws holding them to the master cylinder body. We used this model because the removal
is not so obvious. In the picture above you will see the use of a regular screw driver. Carefully slide the
screwdriver between the plastic reservoir and the metal body and then pry towards the top and twist at
the same time. If you look at the second picture it shows the incorrect way the
screwdriver is used. Pry the opposite direction. The reservoir will pop loose from the base.
Be sure to apply the pressure under the base of the reservoir and not too the metal edge so if any marks
are made they will not show after installation of the new reservoir.

Once you remove the reservoir you will find a o-ring installed in the base inside a groove. Remove this
part carefully. Sometimes it will be crusted in with old dried brake fluid so the use of a scribe
(looks like a ice pic) will be necessary. Be sure not to scar or scratch the sealing surface of the groove.
Clean the inside area thoroughly with carb cleaner or brake cleaner. This cleaning job is best done before
you have installed the master cylinder piston and related parts. Carb cleaner and brake cleaner could
damage the new rubber parts if saturated with the chemicals. Be sure the groove is closely inspected
for any buildup or debris and thoroughly cleaned. A hard bristled brush comes in handy here.

Same as before lay your parts out before installation and compare to the old parts. Shown here are the
new parts ready for installation.

 

Above you will see the before and after installation of the o-ring seal for the base of the master cylinder.
This is the most important part of the installation of the reservoir because it is the main seal for the base.
Check to make sure the o-ring sits in the groove uniform. If you see any areas that are lumpy or
twisted, remove the o-ring and inspect the area of the groove. There may be debris in the groove, buildup
you missed, or the o-ring may be twisted.

Next we are ready to install the reservoir. First apply some silicone lube. Next, line up the reservoir and
place the entire unit on a firm, flat surface as shown. Apply firm pressure and push the master cylinder
down and snap it into place.

This pretty much completes the technical parts of the rebuild and installation. The rest are the basic parts
like installation of the cap and diaphragm and screws for the lid. Most of the additional info will be added
to our brake bleeding section that will soon be added to our Tools and Tips section.

 
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