Master cylinder cap screws seized!!!!

Courage314 · 05-14-2008

Hey all,

Allen from Saint Charles, MO again. I have now gotten to the part where I bleed the front brake on my 1983 KZ550. Well, I have a problem. The screws that hold the cap on the master cylinder are seized. I cannot get them out. I tried the phillips until the phillips slots were strained. I also tried making the screwdriver slots wider with a dremel and using a larger phillips. I cut a slot in the tops and still was unable to get them out with a flat head. I have tried just about all the techniques I know. I am to the point of drilling them out or replacing the master cylinder. What's the general census. I know brakes are important and only the best will do so I am leaning on just replacing the master cylinder in a couple of months instead of bleeding. Thanks in advance.

Allen

CanadianNinja · 05-14-2008

try a screw/bolt remover before you bust out the drill bits. the screw shouldn;t be this tough, do you know if it was loctited?

A2rider · 05-14-2008

Try an impact on it also. I feel your pain, replaced most of my Phillips bolts with allen heads.

If things do go wrong, I bought my master cylinder from a guy on Ebay. PM me if you want the sellers name.

StarGate · 05-14-2008

Mine did the same thing last spring. I used a chisel and hammer to cut a groove in the side of the screw. Then used a blunt tip punch in the notch I created and hammer to break the screw loose so I could turn it with a screwdriver. After that, I completely rebuilt the MC and added 2 stainless socket head screws to the cap. Now this spring I changed the style of handlebars and had to buy a brand new MC to fit them after all that.

OKC_Kent · 05-14-2008

If you use an impact don't beat too hard, I believe yours is a plastic reservoir? When you get it off spread a little anti seize on the new screws.

Courage314 · 05-14-2008

Thanks for the input. I'm headed to take on this problem with some of the ideas I just got from here. I'll fill you in when I'm done. Everyone have a good day.

Allen

A2rider · 05-14-2008

Good luck. The new one I got is metal, let me know what happens.

Kawa 1982 · 05-14-2008

I had exactly the same problem on my KZ1100 A2. Three sharp raps with a hand held screw driver did the trick. As some one said earlier put stainless steel screws in with anti seize compound. You will still need the hand held impact screw driver to get the screws out.

Courage314 · 05-14-2008

Hey all, I finished the job. I was able to make an extra deep flathead slot on the stuck screws, and using the hand impact driver I busted them loose. I was able to finish the job, install new screws with anti-seize, and restore my brakes to perfection with synthetic Dot 3. You all rock!!! Love the help!!! Thanks again.

Allen

Kawa 1982 · 05-15-2008

for letting us know you made it.

A2rider · 05-15-2008

Good for you! We'll keep trying to help, if we can.

05-14-2008	#1 (permalink)
Courage314 Courage314 BTK Intermediate Join Date: Apr 2008 Location: Saint Louis, MO Posts: 129	Master cylinder cap screws seized!!!! Hey all, Allen from Saint Charles, MO again. I have now gotten to the part where I bleed the front brake on my 1983 KZ550. Well, I have a problem. The screws that hold the cap on the master cylinder are seized. I cannot get them out. I tried the phillips until the phillips slots were strained. I also tried making the screwdriver slots wider with a dremel and using a larger phillips. I cut a slot in the tops and still was unable to get them out with a flat head. I have tried just about all the techniques I know. I am to the point of drilling them out or replacing the master cylinder. What's the general census. I know brakes are important and only the best will do so I am leaning on just replacing the master cylinder in a couple of months instead of bleeding. Thanks in advance. Allen __________________ My name is Allen, and my blood is primarily made up of 93 octane. 83' KZ550 99' VS800 Intruder

05-14-2008	#4 (permalink)
StarGate Navy Vet Search & Rescue BTK Expert Join Date: Apr 2007 Location: NE Arkansas Posts: 6,126	Mine did the same thing last spring. I used a chisel and hammer to cut a groove in the side of the screw. Then used a blunt tip punch in the notch I created and hammer to break the screw loose so I could turn it with a screwdriver. After that, I completely rebuilt the MC and added 2 stainless socket head screws to the cap. Now this spring I changed the style of handlebars and had to buy a brand new MC to fit them after all that. __________________ Mike Original Owner 1981 KZ1000-K1 LTD 2000 Suzuki King Quad Refurbish Photos

05-14-2008	#5 (permalink)
OKC_Kent Riding every day! BTK Expert Join Date: Sep 2005 Location: Oklahoma City Posts: 1,018	If you use an impact don't beat too hard, I believe yours is a plastic reservoir? When you get it off spread a little anti seize on the new screws. __________________ Oklahoma City '78 KZ 650 '83 KZ 750 Proud Marine Corp Dad

05-14-2008	#6 (permalink)
Courage314 Courage314 BTK Intermediate Join Date: Apr 2008 Location: Saint Louis, MO Posts: 129	Thanks for the input. I'm headed to take on this problem with some of the ideas I just got from here. I'll fill you in when I'm done. Everyone have a good day. Allen __________________ My name is Allen, and my blood is primarily made up of 93 octane. 83' KZ550 99' VS800 Intruder

05-14-2008	#8 (permalink)
Kawa 1982 US Army, Retired BTK Intermediate Join Date: Sep 2006 Location: Fayetteville, GA Posts: 208	Hand Held Impact Screwdriver I had exactly the same problem on my KZ1100 A2. Three sharp raps with a hand held screw driver did the trick. As some one said earlier put stainless steel screws in with anti seize compound. You will still need the hand held impact screw driver to get the screws out. __________________ It is not the "Quantity" but rather the "Quality."

05-14-2008	#2 (permalink)
CanadianNinja Still On The Kickstand Join Date: Apr 2008 Posts: 29	try a screw/bolt remover before you bust out the drill bits. the screw shouldn;t be this tough, do you know if it was loctited?

05-14-2008	#3 (permalink)
A2rider Banned BTK Expert Join Date: Mar 2006 Location: KCK Posts: 19,728	Try an impact on it also. I feel your pain, replaced most of my Phillips bolts with allen heads. If things do go wrong, I bought my master cylinder from a guy on Ebay. PM me if you want the sellers name.

05-14-2008	#7 (permalink)
A2rider Banned BTK Expert Join Date: Mar 2006 Location: KCK Posts: 19,728	Good luck. The new one I got is metal, let me know what happens.

05-14-2008	#9 (permalink)
Courage314 Courage314 BTK Intermediate Join Date: Apr 2008 Location: Saint Louis, MO Posts: 129	Hey all, I finished the job. I was able to make an extra deep flathead slot on the stuck screws, and using the hand impact driver I busted them loose. I was able to finish the job, install new screws with anti-seize, and restore my brakes to perfection with synthetic Dot 3. You all rock!!! Love the help!!! Thanks again. Allen __________________ My name is Allen, and my blood is primarily made up of 93 octane. 83' KZ550 99' VS800 Intruder

05-15-2008	#10 (permalink)
Kawa 1982 US Army, Retired BTK Intermediate Join Date: Sep 2006 Location: Fayetteville, GA Posts: 208	Thanks for letting us know you made it. __________________ It is not the "Quantity" but rather the "Quality."

05-15-2008	#11 (permalink)
A2rider Banned BTK Expert Join Date: Mar 2006 Location: KCK Posts: 19,728	Good for you! We'll keep trying to help, if we can.

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