just finished the front brake rebuild - ahhhh piece of mind

[GS Jim]

Well, back from test ride and can say brakes are 100% better. The lever now has a normal range of travel, instead of getting hard right from the onset of movement. Since I had it lying around, we went ahead and rebuilt the front MC with a genuine Suzuki parts kit. The calipers have been intirely rebuilt, including new piston seals, dust boots, and spindel o-rings.

Since I've replaced/renewed so much of the system, I guess I'll never know which factors contributed the most to the improved braking performance, but I'm glad it's done!

[GS Jim]

That could make sense especially if the rubber seal tore at all. Did you replace all of the seals?

Yep, all seals and dust boots replaced.

[GS Jim]

When putting that caliper back together you need to use high temperature caliper grease on those sliding pins and bushings. Also, the factory service manual calls for greasing the back side of some of the pads so you might want to check the Suzuki manual to get this detail right.

Hi Ed, I used a liberal amount of high-temp copper based grease (the same as for the exhaust header bolts), and a very thin film of regular lithium grease on the circumference of the pad that goes in the mounting bracket (not the one that gets bolted to the back of the caliper). I was trying to be very careful not to get grease on the face of the pad, LOL

Question: I took pictures of the whole "surgery" and thought I might post a how-to. Do you think a "Caliper Rebuil for Dummies" would be useful to have around here?

[cowboyup3371]

Hi Ed, I used a liberal amount of high-temp copper based grease (the same as for the exhaust header bolts), and a very thin film of regular lithium grease on the circumference of the pad that goes in the mounting bracket (not the one that gets bolted to the back of the caliper). I was trying to be very careful not to get grease on the face of the pad, LOL

Question: I took pictures of the whole "surgery" and thought I might post a how-to. Do you think a "Caliper Rebuil for Dummies" would be useful to have around here?

Actually, there is already one on Basscliff's site...http://members.dslextreme.com/users/...r_overhaul.pdf

Might be able to add to it though.

[GS Jim]

Actually, there is already one on Basscliff's site...http://members.dslextreme.com/users/...r_overhaul.pdf

Might be able to add to it though.

Yeah, I used it as reference for my rebuild. I was thinking something more step-by-step for really newbies (like myself!) with lots of photos. Also, the calipers on Basscliff's site are of the later 1982 model, a little different from the ones on my bike.

Anyway, it's all good. I'll whip something up and if it's useful, great, if not, so be it. I would just like to return something to the site - I couldn't have gotten this far with my bike's resto without it!