Easy fix for front master cylinder with bad site glass, save 150$

[lilwoody]

I waslooking throug the bike for sale and saw a 05 that had the site glass in the master cylinder melt just like mine did. I figure this may be a problem for more folks than just me so here's how I fixed it. I did this to my bike a few weeks ago when I found out the thieves at Suzuki won't supply a reasonable fix for a obviopusly flawed site window that melts in their front master cylinder. A dollar piece requiers a new master cylinder...GMAFB! So I did some good ole redneck enineering (this works on the same pricipal as a boats rubber bildge plug, I'll call it the squishy hose method) and fixed for less than 5 bucks. If I can help some of the other folks out who have the same problem and screw Suzuki I'm happy.
Here it is. You'll need a very small length of 1/4" hydraulic hose (places that sell it will usually give you a scrap piece), a  1/4x3/4" stainless nut bolt and 2 washers. I first took the fluid out by soaking it up with a clean rag and then cleaned out the reservoir as best I could. then remove whats left of the site glass and clean the up taking care not to get any pieces in the reservoir.
Now comes the fun part cutting the hose. I did it with a chop saw but you can do it with a die grinder or as a last resort a hack saw. You'll need to chuck it in a vise to do this if you don't have a chop saw. You are only going to need about 5/8 to 1/2" piece so it makes it tricky. The way I measured it was I put the length of hose in the site glass hole and left about 3/16" out either side and marked it, then cut to fit. It will be a bit frayed, you'll have to live with it. Then it's just a matter of putting it in the hole, putting a washer on the bolt, sticking the bolt through the holeput the washer and nut on the inside and tighten it up until you squash the hose down to fill the hole. I then added fluid and bled a few ounces through it to make sure nothing was still in the master cylinder. It isn't all that pretty but it works! YOUR MUST USE HYDRRAULIC HOSE OTHERS WILL MELT IN SHORT ORDER!
Here's pics of my fix.

[The Buddha]

Oh yea it works wonderfully well ... if you're a crackhead ...
Normal people I dunno ... may have googled it ... and found ... http://www.newrivercyclesalvage.com/sight%20glass.html

$15 and like new again.
Cool.
Buddha.

[lilwoody]

I kind of figured this place would have some of the holier than tho club. Didn't expect it to be a moderator but at my age people don't really surprise me any more. Take the fix for what it is, a quick easy way to get your bike back on the road or a way for a drug addict to tranfer him sel from place to place. doesn't bother me either way. No matter how much you think you know there is always something more to learn, so thanks for the link. I might just try it, in the mean time I going for a ride this afternoon down to the Everglades, just me and my pipe .

[The Buddha]

That link came up ~1 month ago from someone here ... I didn't make it up.
Surprised me too ...
Cool.
Buddha.

[Mdow]

Oh yea it works wonderfully well ... if you're a crackhead ...
Normal people I dunno ... may have googled it ... and found ... http://www.newrivercyclesalvage.com/sight%20glass.html

$15 and like new again.
Cool.
Buddha.

they are nice guys right down the road from me

[The Buddha]

Good Mdow, you posted about this ~5-6 weeks ago ?
Anyway, I also was pleasantly surprised, you can buy the engine oil sight glasses for bikes new from the dealer. I again never knew that. Till ~5-6 years ago.
Sorry lilwoody ... at your age I didn't mean to call you a crackhead. And I am supposed to know "Your age" from your post ?
Cool.
Buddha.

[sledge]

Errmmm....... lets be fair about this, as a get you home bodge yeah its great, as a permanent fix I wouldnt be happy.
Doubt if any UK bike would pass an MOT in this condition.

[gsJack]

I hope the Moderators Union rules don't say I have to agree with the Buddha.....    No problem, it's happened before and I even had a bit of a disagreement with sledge once.     But I think that's a good fix.  Better to fix your known properly functioning master cylinder than buying an unknown used one from a junk yard.

My first bikes didn't even have a sight window on the master cylinder and I see no need for it for myself.  I pop the cylinders out of the calipers to clean them and refill and bleed the system every time I change pads.  Never have added fluid between pad changes or even checked it.

I never thought the fluid would get hot enough in the master cylinder to melt that sight window, could it have been melted by sitting in the hot Florida sun for a long time?  I know the fluid can get hot enough to boil in the wheel cylinders, gotta feel my master cylinder now after a hard run to see how hot it is just to satisfy my curiousity,   Sure glad we don't have those MOT inspections here.   

[sledge]

Long time ago Jack.....we are all mates now 

[makenzie71]

ha s*****th posts relevant info and gets flamed.  that's awesome...:rolleyes: <- Shhhh incognito ...

[ATLRIDER]

Wouldn't be happy with it as a permanent fix, but, well, errrrr.......it's a fix   If it were gonna be a while I'd paint the bolt to match   If I ever get stuck in the everglades cause of a cracked glass, now I have a fix.  Will let ya know if I do.

[The Buddha]

I hope the Moderators Union rules don't say I have to agree with the Buddha.....    
<snip>

GSJack - Its not a junkyard/used item ... that will be a self defeating idea. How many master cylinders do junkyards have 1-2 ... what is 20 of us decided to try it ...
They are selling that round sight glass alone for $15.
BTW I was selling whole brake systems in the last few months from the katana converts ... but this is just the glass. $15 and good as new.
Cool.
Buddha.

[The Buddha]

Has anyone tried buying the sight glass from those guys ?
Cool.
Buddha.

[Pigeonroost]

Jack;

I have not noticed any excessive heat in any of my bike's masters either; but it may be that lil'woody was thinking the "glass" melted due to exposure to the brake fluid.  I'm pretty sure (if my crystal ball is not faulty) that his reference to rubber tubing other than hydraulic hose melting would be due to the brake fluid and not heat.

I can never see a damned thing in those little bitty windows anyway; useless as teets on a boar hog.  If mine breaks. I think JB Weld will get a shot at it, or braze a penny into it.

I am not sure why Buddha flamed lil'woody either; maybe he's on the rag recently since that dude stiffed him.  Anyway, pluging holes with rubber well nuts or improvised hydrualic hose well nuts is pretty common and if you use a neoprene well nut the temp repair will last long enough in the brake fluid to get you home, maybe a long time.

prs

I never thought the fluid would get hot enough in the master cylinder to melt that sight window, could it have been melted by sitting in the hot Florida sun for a long time?  I know the fluid can get hot enough to boil in the wheel cylinders, gotta feel my master cylinder now after a hard run to see how hot it is just to satisfy my curiousity,      

[jeremy_nash]

I am not sure why Buddha flamed lil'woody either; maybe he's on the rag recently since that dude stiffed him.  Anyway, pluging holes with rubber well nuts or improvised hydrualic hose well nuts is pretty common and if you use a neoprene well nut the temp repair will last long enough in the brake fluid to get you home, maybe a long time.

prs

this thread is from over a year ago, doubt thats what the deal was    and in one of my first posts, buddha called me a clown.  my guess is he uses these words whimsicly, not intending to offend anyone, even though most of the time, it comes out to be pretty rude   

[The Buddha]

Yea I call people clown all the time. Its my version of 'duuuude" which IMHO is so 90's. Its not always derogatory, but it will be my pleasure to derogate any one when they need it ... its one more of the many services I have to offer.

The glass breaking or getting pin hole will let water into the brake cyl. So yea it can be welded or bolted up tight, but I intend to check the replacement they are going to send me.

Cool.
Buddha.

[Toogoofy317]

a dime works just dandy too saw another gs with one in it at Universal. Mine is also doing the same thing however could ot be Florida?

[The Buddha]

Dime ... WTF ... you really need a gasket or a put a bolt and tighten it up with a grommet.
I'd really call that a temporary though. Brake fluid eats stuff, and takes in water. Proper sealing is needed.
Cool.
Buddha.

[commuterdude]

I'd really just like a sexy new reservoir to put up there like a CBR has or something.   Ya know, got some bling.   My reservoir is rashed up and all although the sealing and window are fine.

[lilwoody]

It's still working just fine. Not a drop of water inside or break fluid outside.  Break fluid will melt many things, hydrolic hoses is one thing that will hold up to it for sure. Stopping to me is way more important than going, that is why I used it. As for what other folks think, I could give a flying rodents backside.