Brake fluid leak from the master cylinder - Kawasaki KLR 650 Forum
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post #1 of 5 Old 08-29-2011, 11:57 AM Thread Starter
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Brake fluid leak from the master cylinder

So, here is some stainless brake line drama. I swapped the front brake line on my 09 with a russell stainless, and got it to bleed properly, and the brakes work fine. Unfortunately, while removing one of the reservoir cap screws, it got somewhat stripped. I was able to reuse it, but obviously couldn't get it to screw down as tight as I'd like it to (although it is screwed in pretty tight). Fluid is leaking from the reservoir cap. I want to replace the screws but I need to know exactly what size they are. Also, is there any chance that the diaphragm in the reservoir could not be getting a proper seal? I just want to be sure it's done right and get the problem solved. Would it leak if there was too much fluid? When the bike is level, it is just under the top of the window.

Help me troubleshoot, and if anyone knows the exact sizes of the screws for the reservoir cap, please let me know. I already booked a cabin in TN for the weekend, so I need to get the brake fluid leak fixed in the next couple days so I can ride up there!
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post #2 of 5 Old 08-29-2011, 01:12 PM
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rickyp -

Is it a real gusher or just seepage?

If the latter, probably not to worry for a near term short trip.

Off the top of my head I don't know the screw size, but it may be hard to source a good set of screws with the countersunk head.

I'm sorta guessing (from memory) that they are 4mm. You could take them down to your local Lowe's/Ace and see what you can find.

That said, Eagle Manufacturing offers a replacement kit of screws for both the carb and the master cylinder at a very reasonable price. You might be able to get them sent out to you in time for your trip.

HTH,

T

Tom [email protected]

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post #3 of 5 Old 08-29-2011, 01:16 PM
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Quote:
Originally Posted by rickyp3278 View Post
So, here is some stainless brake line drama. I swapped the front brake line on my 09 with a russell stainless, and got it to bleed properly, and the brakes work fine. Unfortunately, while removing one of the reservoir cap screws, it got somewhat stripped. I was able to reuse it, but obviously couldn't get it to screw down as tight as I'd like it to (although it is screwed in pretty tight). Fluid is leaking from the reservoir cap. I want to replace the screws but I need to know exactly what size they are. Also, is there any chance that the diaphragm in the reservoir could not be getting a proper seal? I just want to be sure it's done right and get the problem solved. Would it leak if there was too much fluid? When the bike is level, it is just under the top of the window.

Help me troubleshoot, and if anyone knows the exact sizes of the screws for the reservoir cap, please let me know. I already booked a cabin in TN for the weekend, so I need to get the brake fluid leak fixed in the next couple days so I can ride up there!

Bike Bandit's schem just shows the screws as 4mm. Take one out and go down to a good hardware store. Get stainless allen flat heads.

No eye has seen, no ear has heard, no mind has conceived what God has prepared for those who love him. 1 Cor 2:9
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post #4 of 5 Old 08-29-2011, 06:37 PM
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take a carpenters nail set and tap it with a hammer somewhere on the screw head where u can get a purchase and snug it up remove it the same way when the part is located . or ziptys or duct tape
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post #5 of 5 Old 08-30-2011, 08:20 AM Thread Starter
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problem solved. a friend nearby had a spare set of replacement screws!
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