Front Brake Stuck

[JTGS850GL]

It looks like the brake line goes to some kind of square connection mounted to the front fork, then another line goes from that to the front caliper. What is this called and does it need to be replaced during the teardown?

No, the junction block can stay. It's not a wear out part.

Brake lines are available in so many different lengths. If I just match generally the length of what is already in place will I end up OK?

Yes, you can just measure what you have and replace the lines with the same length lines. That assumes you're not changing the handlebar design or front forks.[/QUOTE]

Are the rear brakes part of the same system controlled by the same master cylinder as the front brakes or are does the rear have a different system?

No, the front and rear are completely independent.

Also, I guess this thread really should be in the Tires/Suspension/Brakes forum instead.

Yes!

[cb1ocker]

Awesome, thanks!

[OldVet66]

Coaxial cable is good to measure exact length. A lot of companies make custom sets of Stainless braided line. cut the pieces banjo to banjo and tag them with what angle fitting you need for each line section, or send them the old lines.

[BigD_83]

Is this the right site?

http://www.rennsportautoparts.com/

I had the town wrong, but yes, those are the guys. They might even have measurements for your specific model, if you plan on keeping everything stock. A phone call is better than email, but they will respond to either.

[cb1ocker]

I drained all the fluid and got the caliper and lines off. I'm guessing the master cylinder isn't supposed to look like this:



Is soap and water going to be good enough to clean all this up with?

[Cyrano]

I tried hard but I can't find the right 'smilie' to go with that picture. But now I'm pretty sure that the return hole is blocked.

You might still be able to save it. At least it's had fluid in it and hasn't dried out. Take it off, strip it down, use lots of brake cleaner spray and see what you can see.

If you have access to a small ultra-sonic cleaner that would help a lot.

[steve murdoch]

Still in liquid form is a bonus. haha.
Usually has a nice aroma too.
Just a tip, when working with the brakes, put a towel over your tank for protection. It can damage the paint if spilled.

[OldVet66]

Right in the middle of that mess is a little cover tab that I guess is to keep crud from blocking the tiny return hole under it in the reservoir. I suppose you will break it like I did attempting to clean it and end up ordering a new reservoir along with the rebuild kit. If I remember correctly that plastic gets a bit brittle. There should always be a little slack in the brake line before it activates the brakes (about 1/4"). You have experienced what happens when there is none.

[cb1ocker]

Do you guys think these brake pads would work in a 1977 GS550B?**

http://www.d2moto.com/1977-1979-Suzuki-GS550-Kevlar-Front-Brake-Pads_p_24404.html

Also, is partzilla.com a trust worthy place to order from? I like that they list all different parts for each system in the bike, but I'm not sure if there's a better kit I can buy somewhere or not, there is a whole lot of information out there on parts, I"m trying to parse it all, but it's a time consuming process.

**At least I think it's a B. The title doesn't really list a model number, and it only says GS550 in the VIN.

[Nessism]

Parts outlaw is one of the forum favorite places to order parts. You might want to check their prices against partzilla before ordering.

Get new seals for the caliper and a master cylinder kit. And don't forget to replace the brake line. Do a full system tear down and clean out. That's the only way to properly service the system.

Regarding the pads, all the various round Suzuki pads interchange. I'd look for a name brand, but that's just me. You might want to check ebay.

http://www.ebay.com/itm/EBC-Brake-Pads-Suzuki-GS-550-750-1000-GS550-GS750-GS1000-1977-1978-1979-/371048196454?hash=item5664322966&vxp=mtr

http://www.ebay.com/itm/NOS-Suzuki-1978-1982-GS1000-1978-1979-GS550-Front-Disc-Brake-Pads-79-2657-/301183401109?hash=item461fedfc95&vxp=mtr

[cb1ocker]

Thanks Nessism.

As for a master cylinder kit, are they universal? Would it be better to buy the exact part number like this?

http://www.partsoutlaw.com/oemparts/p/suzuki/59600-33810/-piston-cup-set

Or could I save a few bucks and get something like this to integrate?

http://www.ebay.com/itm/FRONT-BRAKE-MASTER-CYLINDER-REPAIR-KIT-NEW-SUZUKI-DR650-GS550-GSF400-VL800-/361301642444?_trksid=p2141725.m3641.l6368

I'm not afraid to spend the extra money if it's the better option, but probably like most of us I'm also a big fan of not spending the extra money if I don't have to.

[Nessism]

OEM brake system parts are tried and true. Sometimes the aftermarket seals/kits are okay and other times they are crap. Spending a little more on the OEM parts is money well spent in my opinion.

[cb1ocker]

Getting the snap ring out of the master cylinder to remove the piston is proving to be a lot harder than any of the youtube videos made it look. I bought a snap ring pliers but of course it won't fit in to the cylinder far enough to actually use it. I was able to get a little movement using a couple long screws and the rage of a thousand suns, but now it's stuck. Am I going to end up having to spend money on the entire master cylinder enclosure or is there some way to get this out that I just can't see?

[Eli69]

there are extra long, angled clip squeezer tools. i need some too. z1enterprises sells them. http://www.z1enterprises.com/ItemDet...item=TU15-8279

[cb1ocker]

Thanks, those look like they could work. I'll have to order some if I can't find someone locally that has a pair.