Hey guys, so I've been in the process of attempting to unseize the front brakes on my bike, I managed to free up the pads from the disc however when I was removing the lid of the front brake reservoir one of the pathetic little screws turned to mush when I tried to unscrew it. I attempted to put a slot in it to allow me to use a slotted screwdriver however this turned the screw into even more a mess. Next I attempted to drill into the screw with the intention of leaving the drill bit in place and then attacking it with a pair of mole grips. This also failed as did screw extractors so I've now got mashed up remains of the screw and possibly even mashed up the thread of the hole itself.

Anyone have any ideas on what I can do now? Is it a case of replacing the whole front brake master cylinder? This part seems to be really difficult to come by.

Is this the screw that holds the clip the locks the top of the reservoir ???
Just bend the clip so you can take the top off and get the fluid out. Then take the reservoir off and cut the nylon boss off. It's a stupid thing and you don't really need it.

Evilchicken0 wrote:Is this the screw that holds the clip the locks the top of the reservoir ???
Just bend the clip so you can take the top off and get the fluid out. Then take the reservoir off and cut the nylon boss off. It's a stupid thing and you don't really need it.

It's one of the metal style reservoirs that have two small screws holding the lid on. Has the fluid level window in the front. I'll post some pics, hang on.

The bottom screw hole is the knackered one

Here's another pic

You can actually see the mangled remains of the screw in the second pic clearly

Hi, options are to replace or lots of patience-drill carefully going up in drill sizes & hopefully be left with just the thread & pick it out, then clean with a tap. If this fails there's always the helicoil repair which will replace the thread-then replace the screws with stainless ones so this won't happen again, they're peanuts on the bay. Good luck.

Sorry I thought you meant a 3TJ
Just replace it, you can use one from a 600 as well. You might want to go for a master cylinder from a later bike the res is slightly taller so just check the original type has enough tolerance to the fairing.

If you put on a twin braided hose or race type lines the double banjo bolt into the master can touch the rev counter which is an MOT fail, a later master has the banjo bolt parallel to the bar so you can use a two line system.

freefallfil wrote:Hi, options are to replace or lots of patience-drill carefully going up in drill sizes & hopefully be left with just the thread & pick it out, then clean with a tap. If this fails there's always the helicoil repair which will replace the thread-then replace the screws with stainless ones so this won't happen again, they're peanuts on the bay. Good luck.

Cheers buddy, have emailed a few local companies about helicoil repairing it and will compare the repair cost against a replacement.

Evilchicken0 wrote:Sorry I thought you meant a 3TJ
Just replace it, you can use one from a 600 as well. You might want to go for a master cylinder from a later bike the res is slightly taller so just check the original type has enough tolerance to the fairing.

If you put on a twin braided hose or race type lines the double banjo bolt into the master can touch the rev counter which is an MOT fail, a later master has the banjo bolt parallel to the bar so you can use a two line system.

Thanks for the advice mate. Do you think this one would fit as a replacement?

http://www.ebay.co.uk/itm/YAMAHA-FZR-60 ... SwGvhT~9-H