Front Brake Master Assy snap ring issue

[davestrike]

Ok All,

I finally got the tool to remove the front brake master cylinder to repair it. Started to poke around and scraped the rust away to see inside there, and guess freaking what! The snap ring has no holes!
The snap ring appears to be missing the two little holes to apply the snap ring tool ends into.

Any ideas on how to fix this? Or is it time for a new Master Assembly?

I did find a possible replacement at Parts N More.

DUAL DISC MASTER CYLINDER
Dual Disc Master Cylinder Assembly. Yamaha Style - Alloy body Master Cylinder Assembly with Lever, Banjo Bolt, Banjo Bolt Washers and Brake Switch. High Quality , Low Profile Design featuring 16mm cylinder with 10 x 1.25 threaded outlet. Fits 7/8 inch Handlebars, Accepts Yamaha Style Left Hand Thread, Right Side Mirror.
$76.00US EA. Part#08-0264

Thanks in advance.
Dave

[John]

The new M/C will be your best bet, especially if the holes in the snap ring have rusted away. A long soaking in WD 40 or similiar product may loosen it up enough where you can get a small dental type pick in there and dig it out. If you can keep the piston compressed, maybe you can loosen it up with the pick or small screwdriver, and dig it out from the bottom side of the snap ring.

[cajun31]

By a kit

Dave,

If you can get the remains out I am sure you can get a rebuild kit from Bikebandit. The rebuild kit is about 43.00.

[Ken Talbot]

The ring will have the obligatory two holes. Chances are there is just so much rust and cr@p in there that you just can't see them. Use a dental pick or some other fine point device to scrape around where the holes would be. I'm sure you will find them.

[Pat Kelly]

That parts n more master cylinder works. I have it on both my XS's.

[davestrike]

Thanks All for the suggestions!

Unfortantely, the holes are gone. I used WD40 to clean it up some inside and nada.

So PartsNMore gets some of my money.

If I want to ride this beastie down to Oly in August, I kinda need front brakes.

Dave

[Pat Kelly]

Only if you want to stop when you get there

[cajun31]

Does the back brake work

Although I would not advise it I have read that some folks on this forum have actually ridden with just the back brakes working.

[davestrike]

Very true Pat!

[79XS11F]

That's a lot of rust to dissolve the clip holes away. Was the rubber boot in place or badly damaged? It would be very difficult to remove that clip without damaging the walls of the bore with out the compression holes.
Rob

[davestrike]

79X,
The rubber boot is still in place and in pretty good shape. It appears that someone attempted to remove the clip before and that is when the very rusted holes broke.

Like I said, Parts N More now has $76.00 of my money for a replacement. No way am I screwing around with bad brakes!!

Dave

[fredintoon]

It's a moot point but - - -

Hi Dave,
I'd suppose that if the snap-ring extractor lugs had rusted all away the rest of the m/c would be rusted solid too? Perhaps it's more likely the dreaded PO lost the original and replaced it with an earless one. They slide in OK, it's getting them out again that's hard.
Now that you have a replacement and if you care to experiment, try grinding through the snap-ring with a small tungsten carbide or abrasive ball on a Dremel tool and see if you can't pick out the two halves. Yes there will be a pit left in the bore but you only need a good bore surface further in where the seals are.
You may even end up with a usable spare.
Fred Hill, S'toon.