Suzuki 2 Strokes

Is there a circlip somewhere or do you just pull it out or what master cylinder plunger that is

There is a snap ring about an inch down in the lever end. It's a mutha to get out and equally nasty to get it back in. If nothing else, it will expand your vocabulary. The snap ring must come out to disassemble the unit and extract the piston and other bits.

oh lord i was hoping that was not the answer. all i could see down in the lever end cavern was rust. couldnt even see a circlip. maybe tomorrow i will learn a new profanity. let you know thanks.

i dunno if i can even fit any of my snap ring plyers ends in there maybe thats where the vocabulary comes from

Mike,

Sloosh it out a few dozen times with WD40 and the end of something sharp to get the crud out. Eventually you'll see the ring and its two eye-ends.

Make or adapt a circlip remover - recently I dremelled the ends of my smallest long nosed set and out it came. On a previous m/cyl I got it out using two small, sharpened elec screwdriver tips. Painful the first time. Easy to get a new clean one back in though!

Good luck,
Mike

What I did was cut the L's off two 3/32 allen wrenches. Then ground the tips to fit the holes in the snap ring. Still wasn't easy. I had to extract the piston with vice-grips. As bad as this was, it rebuilt just fine.
In the kit there is a new dust boot. It comes with a circular clip to hold it in place. I fooled with that for about an hour and wound up throwing the clip in the trash. Once assembled, the lever will hold the boot in place.

Use a nail to pull it away from the edge, then a very small flat screwdriver to work it the rest of the way around. Watch your eyes, those things can spring out!

thanks guys ill get to it this eve and let you know

well i got the snap ring out, realized there was a plastic washer and c ring about it, and got those out and then could see the ring. hooked it with a straight pick and got it out. clamped some needle nose visegrips on the piston, and oh what a surprise its frozen in there. so ive got a pool of pb blaster soaking in the piston compartment there. will try again tomorow after soaking

got it out! a little heat around the housing where the piston sits, and gave her a yank, and out she came. ugly stuff in there. so one question, there was a wire c clip and a plastic washer on the OUTSIDE of the circlip which holds the piston in. my rebuilt kit does not include these parts, is there any reason for either of these parts in there?

The wire C clip is meant to hold the dust boot on. I trashed mine. I don't remember any plastic washer