Removing MC Reservoir

[Milo_357]

I would suspect the reservoir is "glued" in place by old brake fluid.  Try wrapping MC with a soaking wet cloth (warm) and letting the water soak into the separation of the MC and the housing.  I'd gently rock the MC res. back and forth until it breaks free. I seriouslt doubt anything will break.

Good luck!

Dell

[Mike V]

In support of Dell and Ken's recommendation...

After the 3 long top cap screws have been removed along with the small phillips base screw at the bottom of the unit, try rocking the reservoir back-and-forth from the base, or front to back as when the unit is positioned on the bars.  
Don't twist, there are 2 small plastic positioning nipples in the bottom of the reservoir that fit into the base.  Do I dare admit I had to use a small wooden hammer handle wedge to create a little seperation between the reservoir and base of my stubborn unit?  Of course I would NEVER advise you to CAREFULLY pry inbetween the base and reservoir.

You might leave it out in the sun to warm it up a bit but as long as all the 4 screws are removed a good secure grasp on the reservoir with one hand and the base with another hand, then working both in opposite directions should get them to come apart. Once you get them to seperate a little try to lift (or carefully pry) the reservoir upwards not to damage the circular o-ring groove in the bottom of the reservoir where it is seated inside the base unit.

Good luck.

-Mike V.    

[79beem]

Glad i waited!
seems Clymer instructions might be on target if there are 2 locateing lugs/nipples. Thanks to all who chipped in on this one,  I'll let you know how i go.

[tvrla]

Right! There are two locating pins, so the reservoir won't turn unless it's up about 1/4".

What tends to happen (my supposition) is this: when topping up the reservoir, it's very easy to get fluid down the cap screw columns and thus between the reservoir and MC. That causes the corrosion. That, and moisture can get in there anyway - it doesn't take much for aluminum to corrode.

That said, the reservoir has a tit that fits into a receiving hole in the MC, with an oring to prevent fluid leaking out. Corrosion has now built up 'above' that oring, and that's what's preventing removal.

With the MC removed, do what you can to get penetrating oil down through the screw holes, or something to handle aluminum corrosion. With a putty knife you can lever up a corner of the reservoir and wiggle a little. Use a heat gun or hair dryer and put it through several heat/cold cycles - lubricating/de-corroding all the time as well.

It's a fiddly job, but somebody's gotta do it!

Take your time and eventually it'll come free without damaging the plastic.