Bleeding issues

[Cdnpt1]

Thats a shame. I seriously don't advise this but when i am absolutely stuck i have used large vicegrips and a screwdriver. If you know you are going to replace the piston, a $25 part from boulevard suzuki, then have it it, otherwise take your time and go easy. As far as the line goes, do a search for custom brake line: this is a great thread by nessism,

http://www.thegsresources.com/_forum/showthread.php?t=114521&highlight=Custom+brake+line

Or, do a search for gs450 brake line on ebay, and you will find a company called rennsport who will make you one custom for about $36 shipped. I can vouch for the line as I just put one on my gs450e. It was a tad long and the tubing is narrower than stock but it works well, and it's black for that stock look. Follow their measurement instructions and it's all good. As far as all other replacement parts I have followed advice on here and gone suzuki parts only. Boulevard has good prices.

[Hoggystyle]

i wish i could find a way to the shop, it would be a great experience, even the constant flak i would get for not owning a Harley Alright, ill start the rebuild this week, get measurements and start sourcing some SS lines. ive found that RonAyers.com is a good place to get oem parts, they seem very reasonably priced. though ebay sometimes has some great deal on OEM parts. Actually i sold a Rifle Scope on Ebay that is sourcing this rebuild entirely! gotta love ebay

[Hoggystyle]

alright so i got the calipers off, but wont be able to strip them dow until i can get to my bosses shop where i can use a vice to get the allen head pins out. i just ordered a piston seal, dust boot, orings for the pin, and piston boots so i can do the front caliper in one go. i am looking into Earls homemade SS brake lines, but have a few questions. for the front brakes, i have one caliper. under the headlight there is a cylinder where the 2 lines connect, can i remove this and run one continuous line up the the reservoir? or is this the MC? i took the cap off the reservoir and the rubber looks fine, but is there anything i need to replace on the front besides the lines and the caliper internals?

[chuck hahn]

loosely rebolt the calipers on the forks and break the allen heads loose letting the forks act as your vice.

[Hoggystyle]

ahhh, thats a great idea! thank you! i would have never even thought of that

[chuck hahn]

Lesson learned myself the hard way..now i loosen everything before i unbolt them..I dont own a vice either!!

[Hoggystyle]

there is always an easier way to do things, looks like you found it there! what kind of grease do you use on the caliper axles? ive read that it should be a copper grease but is there a brand name that you usually go by?

[chuck hahn]

You can get caliper grease pack at the parts store counter for like .50..I just use a little smear of regular grease on mine. check the condition of any orings on the carrier pins as well. Many times they are stuck in there and youn gotta pull hard to get them out and the orings can tear from being old and brittle.

[Hoggystyle]

does only one axle use orings? i just ordered all the rubber parts for a full rebuild and the fiche showed that only one need rings, but it looks like the other is grooved to take them as well

[chuck hahn]

They are bothn grooved but all the ones ive ever taken apart only had them on the one carrier...i never questioned it before, but i would go with what the fiches show.

[Hoggystyle]

ok, just making sure i have all i need to rebuild in one shot.

[chuck hahn]

Inspect in the holes on the caliper bodies to be sure they are clean in there and no small pieces of old orings are up in there too. Does no good to put new stuff into crusty old holes.

[Hoggystyle]

do you mean the inside where the dust boot seals around? i pulled the boot off and there is tons of rust on the inside. i sprayed pb blaster instide the cavity to help remove the axles but im not so sure that was a good idea. i bought brake parts cleaner so ill have to be very liberal with it on the insides to make sure theres none of the blaster left inside. shouldn't be too hard to clean out. as far as brake lines go, what do you use? i am shopping around for ss lines, and the link on this thread shows how to make your own. have you had any experience with this?

[chuck hahn]

Clean every crack and crevice there is..especially the groove the piston seal goes in. As for lines..I just get OEM replacemants myself.

[cowboyup3371]

I have made mine and except for one end I didn't crimp very well they work pretty well. Plus they came out cheaper than buying a full set I thought