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PostPosted: Fri Jun 26, 2015 7:56 pm 
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Joined: Fri Feb 06, 2015 12:47 am
Posts: 174
I needed to rebuild my master cylinders so I found a couple of options for replacing the faded/cracked sight glasses. Some just replace the window with a piece of glass/crystal which lasts forever but has to be sealed using silicone which is ok I guess, but I chose to do it the hard way and replace the whole pressed in unit (18mm). These are $15 each and come with a new o-ring as well, not cheap and will suffer the same fate as the originals over time. I had to get inventive as I thought by using a jack bolt inside the reservoir I would press the unit out. It only pressed the window part out and left the outside ring for me to deal with(not fun). I added a small washer to my device to hook under the ring where the o-ring sits, and moved it side to side many times to work it out evenly so as not to damage the bore. It worked good in the end and I cleaned everything well and pressed in the new unit with a block and hammer(go straight!!) until flush which seals against the new o-ring. I painted them the same colour as my calipers, a metallic graphite, and I polished my brake lever for reduced wind resistance.... Lol. I still have to do the other one so if you need a better pic let me know. The master rebuild kits are still available from Honda. TB


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PostPosted: Fri Jun 26, 2015 10:36 pm 
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Joined: Thu Aug 18, 2005 10:13 am
Posts: 3760
Location: PERTH WESTERN AUSTRALIA
Trailblazer wrote:
and I polished my brake lever for reduced wind resistance.... TB


Great idea,possibly the racer's next winning edge? Image
I'm gonna see your polished brake handle...and add my complimentry wind resistor polished nails. Image


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PostPosted: Fri Jun 26, 2015 11:02 pm 
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Joined: Fri Feb 06, 2015 12:47 am
Posts: 174
Well it's a little much I admit, but I have a generous frontal surface area to overcome(me) so I thought a little friction reduction here or there might help... Naw, I just like shiney things...lol. Was just checking to see who read my posts vs. just looking at the pictures, and you caught it!! Lol. They were a Biotch to polish, and no way I will ever polish a master cylinder again after doing my wife's bike. I blame it on the reservoir covers... It needed something else


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PostPosted: Sat Jun 27, 2015 1:50 am 
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Joined: Tue Aug 03, 2010 12:02 am
Posts: 2147
Location: St. John, Washington
where did you get the site glass? im interested in doing this to mine. i currently have the crystal but didnt realize that they were able to be pressed out.


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PostPosted: Sat Jun 27, 2015 2:58 am 
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Joined: Fri Feb 06, 2015 12:47 am
Posts: 174
nitrosport_5 wrote:
where did you get the site glass? im interested in doing this to mine. i currently have the crystal but didnt realize that they were able to be pressed out.


This is exactly what I used, 18mm and fits perfect. It's not hard to press out once the tool is made and is like driving in a seal or race on install.

http://www.ebay.com/itm/one-sight-glass ... 4ae2f33511


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PostPosted: Sat Jun 27, 2015 1:36 pm 
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Joined: Mon Dec 15, 2003 2:40 pm
Posts: 22512
Location: Chicago
Thanks for the valuable info I am sure their will be many of these needing replaced in the future as these machines age.


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PostPosted: Sun Jun 28, 2015 10:00 pm 
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Joined: Fri Feb 06, 2015 12:47 am
Posts: 174
hoser wrote:
Thanks for the valuable info I am sure their will be many of these needing replaced in the future as these machines age.


Here is some photo's (to help those future sight glass replacements) of the tool I used to press out the sight glass. I used a 1" long taper head 1/4" bolt for this, and any collar that fits a 1/4" bolt(so the inside of the reservoir doesn't get marred). It does not remove the outer ring, both mine stayed in after using this setup. See my first photos on how I dealt with that. I held the wrench on the angle and turned the vertical wrench in the photo to press out the sight glass. The metal behind the glass will be destroyed doing it this way so do not use this if you are just replacing the glass/crystal and want to use rtv. This is for replacing the entire pressed in unit only. I installed the new sight glass AFTER prepping the master for paint so I would not accidentally scratch the new lense, and installed the unit before painting because you will damage the paint hammering/pressing these in. I masked of the reservoir and sight glass to keep paint out and also installed a plug in the master bore(don't want paint in there!!). There are two pieces in the bottom of the reservoir that probably would not survive powder coating, why I chose paint for mine. Good luck with yours, it is a rewarding project for the do it yourselfer. TB


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