Front brake mod 1978 GS1000

[jskellington]

I'm doing the Salty Monk Shuffle on my GS: adding another rotor, bolting on Kawasaki twin-pot calipers with Salty's adapters . . . that was the plan, anyway. But as always, there's an unforeseen complication, and I return once more to the GSR for salvation . . .

As those with the single-disk 1000 know, the disk bolts to the left side of the hub. On the right-hand side there's a black plastic cover that, when pried off, reveals six threaded holes, as if designed to receive another rotor.

The problem I've encountered is that when I attempted to bolt a rotor onto the left side the bolts encounter a solid obstruction after about four or five turns; it feels like there's a plate inside the hub or something.

Has anyone else encountered this when making this brake modification? If so, please help me understand what's going on inside the hub.

Thanks a lot,

Jack

[salty_monk]

Jack,

Got any pics? How much thread have you got? If you have 5 threads in there a shorter bolt should solve it... A stand alone nut will only have about that many threads in it so I can't see why it wouldn't be ok in this case.

Dan

[Suzuki_Don]

Jack,
All you need to do is use a 8mm x 1.25mm tap in each hole and tap them to a deeper depth. I had to do this on my front wheel as well. You need about 10 threads for the bolts to screw into as it is aluminium you're going into and not steel. The 10 threads is the standard for the Suzuki factory wheels. No need to drill anything out, just run the tap deeper into the existing threads of the hub side that previously did not have a disc/rotor on it.

[jskellington]

Thanks for the replies. Dan, there's probably enough thread to run in a shorter bolt, but the beauty of Don's approach is that I get to buy a gizmo I don't already own, i.e. a tap, thus giving the ailing world economy a microscopic boost and giving me a bit of middle-age fun . . .

The GSR, as always, comes through . . .

Thanks again, fellas.

Jack