Seeking comprehensive list of inspection/parts/procedures for rebuilding brake system

[MoeHalappi]

Disclaimer: Noob here - I'm not so adept at moving around/finding the info that I am seeking - but this is an AWESOME resource for GS owners.

I'm looking to rebuild the brake system on my '80 GS 1000G (45 K miles - lots of no-ride time by previous owner).
They were fine this past summer, but now bike is down for winter/comprehensive going over/maintenance.

I have new SS lines/banjos and crush washers, but upon closer inspection of components I think I might as well just "do it all". (fluid f and r is cruddy, and I'm assuming that the calipers could benefit from a rebuild - MC is aftermarket w/aluminum body and no sight window).

Please suggest or provide either:
A comprehensive list of things to inspect/overhaul and how to recondition them OR suggest links in GSR that I have missed.

AGAIN - I'm sorry if I have missed obvious posts (content in many posts is difficult to determine by Title) and appreciate any help I receive.

Now the kicker - I'm on a tight budget and don't mind wrenching - so please, no replies that I should just buy a new bike - I love this one! It may be 30 years old, but it rocks - even more so after I'm done working on it!
THX

[chef1366]

Do you have a manual? It has pictures and everything.
I'd only buy NOS Suzuki parts.

http://www.mrcycles.com/

[Shin-Ken 1074]

Hi, I agree with Chef1366 about using genuine parts for the brake rebuild. I have just bought the Suzuki brake caliper kit for my 1982 GSX1100 so there is a good chance the kit is available for your GS. The cost of parts is much cheaper in the States so your budget shouldn't blow out to much, and no matter the cost, brakes that work can be pretty handy on a bike so they are one area that should always be done right. Let us know how it turns out, cheers.

[Nessism]

You can pop the pistons out of the calipers using compressed air, grease from a grease gun, or with brake fluid from the system itself. Once the pistons are out inspect them closely, they can be reused as long as there is no corossion pitting. You can reuse the rubber seals and dust seal if they are in good condition although replacing them is always recommended since they are rubber after all.

I recommend scrubbing down the caliper body and all the parts using Simple Green. Obviously, everything needs to be completely dry before reassembly. Use caliper grease on the caliper sliding pins, not general purpose grease, and only use brake fluid for lubing the piston seals before assembly, nothing else is acceptable.

Same business for the master cylinder, dissemble and clean. None of this stuff is hard, just take your time and everything should sort it's self out.

Good luck.

[MoeHalappi]

Brake rebuild project

Thanks for the replies - Clymer manual (used) on the way.
As for genuine SZ parts - they're out as I (perhaps foolishly) spent $240 on SS lines and banjos form a local place that was going out of business (no returns/exchanges) - as far as I can figure, as long as fluid is behind the pistons in a clean/rebuilt system the brakes will work - NO?
I'm assuming a caliper boot kit and obviously fresh fluid - anything else(other than the usual time/beer/elbow grease)?

[hampshirehog]

As long as the caliper seals are ok and the pistons aren't pitted or scored (in either case, allowing fluid to leak past the pistons under pressure or air to be sucked in) your assumption is correct.

If you need new pistons I'd recommend getting stainless - these guys have them:

http://www.wemoto.com/bikes/Suzuki/GS_1000_GT_Shaft_Drive/80-83/