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modified: 08/22/08
Brakes
Note: Email addresses
and links listed in this Q&A section may no longer be valid!
DATE: September 6, 1999
QUESTION: Brake swap info needed - 1981 GS1100EX
I picked up my bike this spring and have been reading your site
quite a bit. My question is regarding the brakes. The rear has 2
pistons in the caliper while both of the front have a single piston.
I don't have the anti dive brakes. Some of the Q&A's mention
dual piston calipers for the front on later models. Which bikes have
these and can I mount them on my bike?
I will be ordering the steel lines this winter and would really
like to upgrade these a little. I know you didn't recommend this for
some other riders with smaller bikes but if I have a problem I can
always go back, so please tell me if it's possible. I can order the
calipers through Suzuki, I assume.
RIDER: Quintin Sauer
REPLY: Malcolm Evans
Dunno about that but a very common mod here in the UK is Nissin
GSXR slingshot brakes. These will fit straight onto GS 1150 legs,
other models can be made to fit with brackets and a spacer washer or
two. This has transformed my GSX 1100 EZ from "I'm gonna stop
eventually" into something that I only need two fingers to stop
dead from 145+, using the stock disc.
Go hunt some up at your junkyard, they are double opposed
piston Nissins, they are fitting them on the GSF Bandits now.
DATE: May 21, 1999
QUESTION: Changing brake calipers - 1979 GS750
I also have a new question. Can change brake calipers on my 1979
GS 750 to improve braking? For example double calipers from a later
model GS. I am going to change the brake lines into steel braided
ones.
RIDER: Edward Goossens
REPLY: Frank Perreault
I would change the brake lines to the steel braided and left the
calipers alone. The added unsprung weight of the bigger,
heavier double calipers is likely to throw the balance of the bike's
front end completely off. It really isn't worth the trouble in
my opinion.
DATE: April 23, 1999
QUESTION: Brakes - 1979 GS750
What's the ideal method for pressing back pistons when replacing
disc pads? The Clymer manual is vague on the subject. Thank you.
RIDER: John Mason
REPLY: Frank Perreault
I use a big beefy metal 'C' clamp being careful not to damage
any of the brake surfaces, especially the brake piston. Take
the cover off of the master cylinder, take some fluid out and put
the 'C' clamp on the brake and turn the 'C' clamp handle to press
the piston back in the brake assembly.
REPLY: Zack Schultz
A 'C' clamp works fine. To prevent the damage that Frank
mentions, use the old pad as a spacer between the clamp and the new
pad.
REPLY: John Mason
Thanks for the reply, Frank. It happens that I've got a beefy C
clamp hanging from a nail right near where I park the bike in the
garage.
DATE: August 24, 1998
QUESTION: Anybody have a 1983 GSX1100ES? Bypassing the
anti-dive brakes.
Hi Suzuki lovers!
I've just recently discovered this wonderful site and I must say I
like it. I'm a bike fan from Sweden at the age of 23. I'm riding my
second bike now, a 1983 GSX1100ES (old frame and double shocks). My
first bike was an 1985 RD350LC, which is very fun to ride when the
curves just keeps coming and you like to pop the front wheel into
the air every now and then.
Anyway, I've noticed that the 1983 GSX1100ES isn't mentioned
anywhere here and I wonder if it's just a very rare bike or has it
only been sold in Sweden? I also want a description about what
happens when you remove the anti-dive plunge unit and replace it
with a solid sealing plate. I've heard that this will improve the
action of the fork....!?! Thankful for answers. Regards
from a cold Sweden!
RIDER: Mattias Edberg
REPLY: Frank Perreault
There aren't alot of these bikes around but there are a couple
listed in the 1100cc Registry. You may want to contact someone
listed there.
As for the brakes, I'll have to let someone else answer that one.
REPLY: Bob Frisbie
I ordered a copy of Motorcycle Reports from Ian Smith
Information (he advertises in the back of all the big motorcycle
magazines). And, I got reprints of articles on the GS1100E I have.
Several of the articles claimed that the antidive units were making
the brakes spongy and recommended disconnecting them. One said to
replace the long banjo bolt (for two hosed) in the brake cylinder
with the single banjo bolt in the antidive, then toss the short
hose. That's what I did and replaced the hoses with steel braided. I
didn't replace the antidive's with anything, just disconnected them.
So far so good. The brakes are really firm but the bike does dive a
lot. I think I need to add a bit more fluid to the forks, maybe some
more air. Anyway, I've got a few hundred miles on it since I
did this and haven't had any problems.
REPLY: Guy
I have an '82 1100 Katana.
The anti-dive units and the whole front end assembly is a bit
of a dinosaur, but it can work.
The biggest single front-end problem is the fork springs. The
originals are soggy, spongy, squishy or whatever else you can
translate it to.
Replace the springs with White Power, or my preference,
Progressive. The preload adjustment must be got right with your
weight and that of any pillion. I weigh 76Kg and used a 20,mm spacer
made from 25 mm diameter nylon bushing for the Katana forks. Yours
are different. Measure the new springs against the old to arrive at
approximately +5mm with a spacer for the start point. You will only
just be able to get the caps back in. Ride it around with the
preload adjuster on softest setting for at least a week to get used
to it, then ask the question "is it too hard, or too
soft". Then shave the bushes to achieve the right
"feel".
The only way to accurately measure the oil in the forks is to
remove them, remove the spring, compress them fully, then measure
the height from the oil surface to the top of the fork. Use this as
the start point for all measurements. You will be amazed how
careless people will have strange front suspension.
I use Shell Quaddro oil as it maintains its viscosity in a
wide range of conditions. Thicker oil gives me sore shoulders on
rough roads, where I want suppleness in the front end. This is also
a reason NOT to use a fork brace - it makes it a bit too stiff.
Next, the anti-dives actually perform a damping function
where they sit and the internal damping orifice is partly closed by
the brake operated plunger moving the spool valve. So, by removing
the anti-dive and blanking off the two holes, there will be a
popping of seals and general wailing and rending of garments.
If you want to remove the anti-dives, it is necessary to
drill the inner tube to allow the oil to pass. The size and placing
of these holes is important. It is also possible to insert
"cartridge emulator" valves at the bottom of the damper
tubes and remove and blank off the anti-dives.
Gives a good result. Talk to Progressive or White Power.
For myself, I found that the new springs and close attention
to fluid height and viscosity solved most of the gripes.
My mate and I are working on the solution to the brakes and
sponge feel to the brakes and have found a small number of
unaddressed problem areas. I will report these as soon as we have
got to the bottom of the problem. The main one seems to be poor
maintenance of the sliders on the caliper, with the grease going
hard or washing away and with metal on metal in the slider, allowing
the caliper to twist slightly while taking up under pressure. This
appears to cause the pads to wear at a slight angle, meaning they
are not flat on the disk and reduce area, giving spongy feel on
takeup as well as reduced performance. The pair of machines we use
are in different parts of the country, mine in the city and his in
the country and we have slightly different complaints across the
same set of symptoms, mine in the city showing more pronounced
"angling" on the pads. This causes disk wear too, with
higher point pressures.
DATE: June 11, 1998
QUESTION: Brake line replacement - 1979 GS425E
My daughter is working on my '79 425E which has about 25,000
miles on it. Always garaged except for the past 2-3 years when it
was parked [uncovered] in all kinds of weather when my son had it in
NY and MI. The front disc brake worked fine, but as it is almost 20
years old I advised replacing the brake hose, and recommended
rebuilding the master cylinder and brake caliper. Is this parental
overkill? And where could I buy rebuild kits for the master cylinder
and caliper?
RIDER: Chuck Duarte
REPLY: Frank Perreault
I would change the brake hoses since those tend to crack when
exposed to the elements, especially after 19 years. As for
rebuilding the master cylinder and calipers, I would check them out
but I wouldn't bother rebuilding them unless they don't work, leak
or just look questionable. Make sure to replace all the brake
fluid when you replace those hoses.
DATE: March 22, 1998
QUESTION: Where to find stainless steel brake lines - 1982
GS1100GL
I have noticed alot of mention in the Q&A section about
installing stainless steel brake lines. I have a 1982 GS1100GL
that I love dearly and I would really love to make the brakes a
little better. Where do I get these brake lines and do they come
ready to install or do I have to make them up myself. I don't
really care I just want to know ahead of time as to what to expect.
Thanks for the help and keep up the good work with the
site. I currently own 3 GS model (1981 GS1000L, 1982 GS1100Gl,
1982 GS450TX) and I love being able to come here to find
information.
RIDER: Rob Hatfield
REPLY: Frank Perreault
A good place for these, if they still carry them, is at MidWest
Action Cycle. Call them at 1-800-343-0608 or macycle@execpc.com.
DATE: March 22, 1998
QUESTION: Ticking brakes on a 1982 GS650E
I ride a GS650E, '82, about 18K miles, mostly commuting. Last
Spring a low-speed accident led to repairs. No fork or chassis
damage: cut a
tire, whacked off turn signal stalks and mirror, bent handlebar end,
cracked windshield. Took it to a shop I have used in the past with
good results, an honest and capable outfit in my experience. Brakes
were low.
Anyway, on the front so I said why not replace the pads as long as
ya gotta replace the tire. I usually ride with earplugs (if you
don't, read the Motorcycle News research articles about it), and
replaced the dinged helmet with a Shoei K9. Quiet. Too quiet. About
a month after I was back on the road, I dropped the earplugs in the
gravel, and shoved them in my pocket to wash later. Riding without
foam in the ears, and with the faceplate open on the helmet in warm
weather, I could hear a rapid loud tick that seemed to be "up
front". Speed on tick varied with road speed, but NOT with
engine speed. Tried with clutch disengaged, kept ticking. Killed the
engine entirely on a hill, kept ticking. Touched the front brake
lever, tick stopped. Rode a ways with the brake lever free, tick
started again.
Took it back and described the noise. Next day, the
"wrench" swore he had re-checked the brake assembly,
"rode it around the lot", couldn't
hear a thing, nothing wrong. Rode another month, still ticking.
Couldn't see anything myself, but what do I know? Got nervous, took
it to another shop, this one a Suzuki dealer. Maybe it's a bearing
giving out... so they replace the front wheel bearing assembly,
proudly announce they found a couple of bad bearings, hey, it's old,
we replaced 'em and everything is fixed. PS, they "rode it
around the lot and couldn't hear anything". Well, I looked at
the old bearings, and yes, they needed replacing. He was closing, I
paid, saddled up, took off for home. By the end of a half mile I
knew the tick was untouched (but the lights had gone off at the
dealers, of course.) I needed the bearing change, OK - but still,
the sound of metal on metal with every rev of the wheel is giving me
the willies, wondering what's finally going to dissolve under me, at
speed, in traffic, one of these days. Neither shop is in a hurry to
tackle this again (honest if not courageous fellows...), and I have
neither the tools nor the experience to tear into what professionals
can't handle. Then again, the professionals "ride around the
lot" with their fingers on the front brake lever, and can't
connect this safety measure on their part with what I keep trying to
tell them about touching the brake lever killing the noise. Duh...
Anyone got a line on this? I keep thinking it's gotta be in the
brake assembly, but I can't see anything out of alignment or with
loose parts sticking out where they shouldn't. No, I'm not going to
ride with the brakes on, and no, I don't want to sell this bike.
Help!
RIDER: John F. House
REPLY: John F. House
Recently two separate readers of the page sent mail suggesting
the speedo cable, which I had dismissed because there was no flutter
in the instrument display. Tried it. Bingo! Thanks to you and your
readers!
DATE: March 8, 1998
QUESTION: Brake fluid leaks - 1981 GS450L
I bought an '81 GS450L recently and have a problem with the front
brake. 1) There is something greasy (I'm quite certain it's brake
fluid) on the right hand side (wheel side) of the rotor. 2) The
front brake is soft. The handle comes all the way to the throttle
grip when I apply enough pressure to stop the bike after I release
the rear brake when coming to a stop. There is a little bit of fluid
leaking from the master cylinder. It looks like it is leaking from
where the plastic reservoir meets the master cylinder.
I would be very grateful to anyone who could give me information
concerning what I should do to repair the problem. Thank you.
RIDER: Aaron J. Orr
REPLY: Frank Perreault
It sounds like your seals are gone on the piston in the brake
caliper. Also, it sounds like you have a bad O-ring or
two in the master cylinder. All this leakage is allowing air
into the system making things appear spongy. The system will
need to drained and both assemblies torn apart and rebuilt.
DATE: November 10, 1997
QUESTION: Front end conversion
I very much enjoy my 82 GS1100 E. I have done a few things to it
and it has always been reliable and fairly powerful, now to make it
corner and stop. PM does make a complete brake replacement kit
(drool) but this does nothing for the forks. Has anyone done the
GSXR 750/1100 front end conversion? I am able to find lots of
suspension parts for these, plus they come with good brakes. Maybe
not just the GSXR series, but a much newer Suzuki sporting bike
front end.
RIDER: Douglas J. Berry
REPLY: Bill Chandler
I know a guy in Las Vegas who has done this type of conversion. Drop
him a line and see if he can help you. Contact: Scott,
Email: AMSARACE@aol.com
DATE: November 4, 1997
QUESTION: Spongy brakes
Hi Frank, my name is Ralph Cuomo. I live in northern Maryland and
own an 82 GS1100 E. Bought it brand new, has 32,000 on it. I thought
I'd contact you directly for an expedient answer. I need to redo my
front brakes. Very spongy. Have original brake lines. Have
disregarded the anti-dive system. Some say replace the lines, other
say rebuild master cylinder. Probably need to do both, but I thought
I'd pick your brain first.
- Local guy says I have to replace the plunger in the cylinder
($45.00). I thought seals would be sufficient, what do you
think? No leaks anywhere and I've bled the brakes. I never had
the tell tale pulsating feel in the lever which is common due to
disc warpage, so I don't think the disc is a problem. However
give me your feedback on that.
- Know of any cafe or bullet type fairings that will fit without
changing the headlight?
- I have had an oil leak thru the front of the head gasket since
about 11,000. compression is slightly lower in 2 or 3 (can't
remember). Performance is excellent so I haven't done anything
with it. Think I should change the gasket, or live with it? My
only concern has be warpage, however performance had not
suffered. I do all my own work and do service at regular
intervals, however I firmly believe, If ain't broken, don't fix
it.
I have learned alot about this bike in 15 years. When I get a
chance I will share my thoughts and experiences with the GS/site. I
lived in Europe for five years and shipped this bike instead of
furniture. I have to admit that there are some European spec parts
on the bike but nothing major.
RIDER: Ralph Cuomo
REPLY: Frank Perreault
- Noting that you don't have any leaks, I think changing
seals and plungers would be a waste of time and money. I would
change the brake lines over to steel braided lines. When I
changed mine, it made a dramatic difference in how solid the
brakes felt. In fact, if you look through the GS Resources
registry you'll notice that that is one of the first, and most
popular changes, that everyone does. Spongy brakes is the reason
for it.
- Not really. Can anyone else help here? Of course, the next
question once you do find a manufacturer of a fairing, is
whether it is still available or not.
- This I would take care of. I would first try retorquing the
head without changing the head gasket. You will need a good
quality torque wrench for this and make sure to follow the
correct tightening sequence. If it still leaks, then change the
head gasket and retorque.
I've found in most cases, retorquing will take care of it. As
for the leak not affecting performance, this is not true. If you
are seeing a compression drop in cylinders 2 & 3, you're
losing power. The 1100 is such a beast of an engine, that you
probably didn't notice the gradual loss of power.
So I'd get the head taken care of in order to get back the power
and avoid any possible head warping problems. It shouldn't cost
much whether you decide to do this yourself or let a shop do it.
A good torque wrench would cost you about $50.
Feel free to forward your stories to the GS Resources
Editor-In-Chief Peter
Huppertz . Peter is located in the Netherlands, so you two might
have something to talk about.
REPLY: ltate@intranet.on.ca
Saw your letter in the Q&A; change the brake lines, for
sure they've had the biscuit after all this time. Best to go with
steel-braided lines. Make sure you keep the fluid fresh; I kept
forgetting and after finally doing it this year can't believe the
difference. Ditto for watching the pads, again, I haven't looked for
years, literally, and couldn't believe how oddly they'd worn, all
four different. New pads and fluid and a good bleeding (I have steel
lines) and it's like a whole new set of brakes.
DATE: October 21, 1996
QUESTION: Brake failure
I have a problem with the brakes on the above mentioned bike. The
brakes are new as of 10-18-96. They have been bled, by a
professional, and by myself. My problem is that they seem to be
holding until I ride it, and then there are no brakes at all, on the
rear only. What do I do. I am also loosing fluid on my back tire.
Please help if you can. I would also like to find a book (manual) on
this bike. If you know how I can obtain one, please let me know.
RIDER: Bryan
REPLY: Frank Perreault
Because of the leaking, it sounds like a piston seal in the
caliper may be bad. As for the manual you might want to try to
contact Clymer Publications, Repair Manuals ,P.O. Box 12901,
Overland Park, KS 66282, Tel: (913) 967 1713. Hopefully, they'll
have the manual for your bike. |