While I was adjusting the angle of the brake lever, the top bolt broke off in the hole.  Then I went to the hobby shop (on AF base) and used their tool to tap it out then rethread, but his damn tool broke off in there too,  cheap a$$ tools.
I was just wondering if anyone knew a site where I could get a replacement master cylinder for a '04 gs500.
I would go to the local shop but they are open only 4 days a week and short hours, plus charge up the whazoo since this place is so.......can't think of a word.
Thanks.

Few Options,

First since I assume they have used the same master cylinder into the 04 model year as they did in 2002 at

BikeBandit.com shows the master cylinder to run about $170USD

http://houseofmotorcycles.bikebandit.com/partsbandit/oem_schematic_view~schem_dept_id~718221~section_dept_id~1~section_dept_name~OEM+%28Stock%29+Parts~dept_type_id~2~model_dept_year~2002~model_dept_mfr~Suzuki~model_dept_id~703278~model_dept_name~GS500K2.asp#stay

RON AYERS~$130USD

http://www.ronayers.com/fiche/300_0322/front_master_cylinder/front_master_cylinder.cfm

Keep searching you will find more,

but check with the rest of the memebers to find out if the master cylinder is the same through '04

Heck maybe even another member knows how to fix it

Quote from: AznboytpkWhile I was adjusting the angle of the brake lever, the top bolt broke off in the hole.  Then I went to the hobby shop (on AF base) and used their tool to tap it out then rethread, but his damn tool broke off in there too [...] I was just wondering if anyone knew a site where I could get a replacement master cylinder for a '04 gs500.

Just a minute.  Are you sure it's the master cylinder that needs replacing?  (And if so, you still have to remove the old one, right?)

Anyway, assuming for now that the 2002 parts are the same as the 2004, identify for us which item is broken.  If you can't find it on the Front Master Cylinder page, check the Handle Lever page.

It's the front master cylinder.  Bolt No. 8 on the diagram broke off past the U shaped bracket in the threading of the master cylinder, then the tapping tool at the shop broke off in the same spot after getting most of the bolt out.

Or rethreading tool....forgot which one

Gotcha.  Before springing for a new master cylinder I would try to go the EZ-Out route.

If that is what the guy at the shop used, and he broke off the EZ-Out-type bolt extractor ... then ... uh ... Hmmmm ....  :dunno:

well if it is cheaper than getting a new one dremmel the broken tool out get a good drill bit and tap it out to whare you can put a helicoil in.

forgot the link. http://www.emhart.com/products/helicoil.html

OK you broke the bolt... not boogered up the threads ... OK Left handed drill bit and drill it out, check if threads are OK then install Helicoil if needed.
Cool.
Srinath.

Anyway, assuming for now that the 2002 parts are the same as the 2004, identify for us which item is broken.  If you can't find it on the Front Master Cylinder page, check the Handle Lever page.[/quote]

From the Cylinder link, what is #9 (protector)
Is it the whole unit (case) or is it pointing at something inside the case?
On hillsboromotorcycles.com, it shows that part as $0.46.
I was wondering if that is what bolts #7 and #8 bolt into.

hmmm

I'm pretty sure that you can't buy the brake fluid reservoir seperately.  Even if you could, NO WAY would it cost 46 cents!

The "protector" must be a small piece inside.  :dunno:

Yeah that's what I thought, darn  

Quote from: KerryI'm pretty sure that you can't buy the brake fluid reservoir seperately.  Even if you could, NO WAY would it cost 46 cents!

The "protector" must be a small piece inside.  :dunno:

I assume that's the bellows-like gasket inside the reservoir that allows fluid levels to fluctuate while still keeping air out.