brake reservoir top up

[donniemateno]

i went to top up my brake reservoir as the brake felt a little spongey

i went to undo the bolts to remove the reservoir cap only to find they have already been rounded by previous owner as they have been sprayed pink! as well

i am just wondering where to go from this?

either to buy a new reservoir unit from somewhere

or drill the old lid off and find some new bolts
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Current bike: Honda CBR 600 F3
Previous bikes: Honda XR 125L5 , BMW 800 ST, Honda CB500

[Hetzer]

Bolts? They should be flat-headed screws.

If they're screws try super-gluing something of the same size to their tops and twisting on that, you never know.
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"There's the horizon! Ride hard, ride fast and cut down all who stand in your way!"

[anthony_r6]

Start with a small drill bit and go down the center of the bolt. Get slightly larger until the screw caves in, or just drill the head off (be careful not to bore into the plastic) and it should just slide off the top. Those screws won't be hard to find.
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Ted : "Maybe he's agoraphobic."
Dougal : "Jack scared of fighting? I don't think so, Ted."

[c_dug]

Impact driver is your friend.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Hetzer]

[c_dug]

I suppose maybe not the brightest idea

You can get small impact drivers that are designed for that kind of thing though, not that I've ever seen one in a shop.
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I am a bellend, I am a man of constant sorrow, I am a gummy bear, I am a rock.

[Kickstart]

Hi

If it is a combined master cylinder and reservoir of metal construction then an impact driver would be my first choice.

Failing that drill the heads off the bolts and the cap will lift off, then you can use mole grips to remove the remains.

The bolts almost certainly have a countersunk head.

All the best

Keith
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Traxpics, track day and racing photographs - Bimota Forum - Bike performance / thrust graphs for choosing gearing

[Hetzer]

[Kickstart]

[Casper]

Used an impact driver myself a few times with no trouble. I tend to change the screws for allen bolts now and keep them clean.

[kestrel]

[Kickstart]

[Hetzer]

[brythered92]

if possible at all hacksaw the exposed part of the head on the bolt then flat head to get them out
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r6 99 quill pipe ....

[Kickstart]

[Nick 50]

File 2 edges either side of the bolt to fit a spanner on to.
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Current Bikes: ZX7r 97 (Black Beauty), VFR400 NC24 (The banana)
Previous Bikes: Aprilia Tuono 03 (The Beast), CBR600f (97)
First bike: A GZ125 Lemon.......

[Walloper]

If you top up then you will have to mop up if you change the pads later.
Check the pad wear.
Brake systems have enough fluid in the reservior to complete a full wear cycle. If not below the Low level leave it.

If spongy then there is a brake syatem problem low level will not cause a problem unless it is empty.
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W-ireless A-rtificial L-ifeform L-imited to O-bservation P-eacekeeping and E-fficient R-epair

[donniemateno]

i am looking to top up because from what i can see there is no fluid in the reservoir! it looks empty i cant find out until the cap is off. the pads are looking very thin as well

but anyway the heads of the screws on the cap are torx counter sunk

they are neither 10 nor 15 their a happy medium which i dont have and since the previous owner looks to have tried to remove them already they arent really 15 now

i am thinking i might have to go with the drill option to take the heads off and then replce the bolts
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Current bike: Honda CBR 600 F3
Previous bikes: Honda XR 125L5 , BMW 800 ST, Honda CB500

[dodgydog]

[flumpy7]

[EazyDuz]

Dont think the brakes would work at all if its empty
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[Kickstart]

[donniemateno]

i took a measurment of the pads today and they are very thin to say the least....0.6 mm of thread

i will buy some off ebay ( and not sue the bike as the brakes are unbelieveably crap now , Rear brake is good though ) and im probably going to buy a new brake lever / reservoir assembly as well as i have noticed when i apply the front brake my brake light wont go out unless i push the lever forward and i can see what looks like a small switch which is just hanging and when i push it back with my finger it just pops back out and moves around quite freely. it isnt "located"

im just hoping i can find a assembly all in one as the ones i found on ebay are for cb400 etc

after a bit of research its a brake lever stop switch which would fix this problem not a new lever.....doh!
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Current bike: Honda CBR 600 F3
Previous bikes: Honda XR 125L5 , BMW 800 ST, Honda CB500

[donniemateno]

finally had a chance to look at the reservoir again!

anyway i tried a hex head socket to undo one of the bolts and just spun

so I'm guessing the best bet as mentioned before will be for me to just drill these out and get the remaining thread out with mole grips?

just a quick question does anyone know what size thread the new bolts/screws will need to be?

otherwise my bike won't be in use for a bit while i look for some

any help mcuh appreciated
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Current bike: Honda CBR 600 F3
Previous bikes: Honda XR 125L5 , BMW 800 ST, Honda CB500

[Raffles]