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I'd try a very small easy out. If you don't have one that small, try a drill bit that's a little too big for the hole, but not on a drill. Turn it in with some pliers so it bites into the brass fitting and then try to pull it straight out. The brass is pretty soft so it should bite in pretty easily.
 
Discussion starter · #24 ·
Update: Hayes got back to me and said to remove the lever, pull the piston, and push the olive out from the other side.
Hopefully, I'll have time to try that tomorrow after work.
 
did the barb come out or was it one of the 1 piece barb/olives?

My thought if its the barb/olive combo-(so the barb is still there).. Id just grab it with a pair of needle nose pliers and yank it out..

if there is no barb and only the olive is stuck inside.. What about using a small internal bearing puller.. The top edge would grab the top of the olive and pop it out.. (thinking out-loud here)..
 
if there is no barb and only the olive is stuck inside.. What about using a small internal bearing puller.. The top edge would grab the top of the olive and pop it out.. (thinking out-loud here)..
It would have to fit inside a 2-3mm hole. Is that even a thing?

Anyhow OP. What's the scoop? We're on the edge of our internet seats out here.
 
To be honest.. im not sure if the internal bearing removers go that small.. But worth a look....

What about some hemostat pliers?

My feeling is-- hayes is going to be slow to respond.. So my goal would be to yank that olive out with some hamfisted brute force.... Break or work.. those are the two options.. If i ruin it in the process-- id just buy another master and move on... But that is me..
 
Discussion starter · #28 ·
The barb and olive are one piece and ridiculously tight. There’s no way to grip any edge; I tried inserting a screw thinking I could pull it out, but the center just deformed.

So, the piston didn’t want to come out from the back. I took a pic and sent it to Hayes and they said they are going to send a new MC.

I’m assuming whoever installed this just cranked the nut way too tight so the olive was practically smashed.
 
Discussion starter · #35 ·
Just for the record... I'm no dentist.😅
And, I only paid $214 for BOTH brakes (delivered)! Back when CRC used to have good deals (before they ruined the website).
 
Discussion starter · #37 ·
$214 is a screaming deal. I paid $300 for a full set and was very happy with that price. Now the MC + lever is $150 at most places.
Yeah, it took me almost a year to install them because I didn't need them when I bought them. I couldn't pass up that deal.
 
Discussion starter · #40 ·
Just to close this out… Hayes shipped the lever really fast, it was simple to install and easy to bleed. These are my first (modern) Hayes brakes and I think they are now my favorite brand (over Magura).
 
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