GS550E Brake Swap tutorial with Photos

[AOD]

I agree the breaks are crap. Even worse two up.

Yeah, that was the worst part about my 550 too, especially two up. Since I ride 50% of the time two up, the 1100 was a good move.

If you decide you don't want to go to the trouble of doing this fork swap mod. Do yourself a favor, get a master cylinder off of a late model anything! While not exactly "sportbike" brakes by any means, the master cylinder alone made the single disk caliper feel much stronger.

I thought about this too...since the 26 year old master cylinder just can't be functioning as good as it used to. The seals go bad, parts wear, etc. The only problem with late model stuff is they do not have a mirror install tapped bung, so you'd have to use bar end mirrors or find another way to attach mirrors.

You guessed It...the rear tire was locking up because the front brake was finally doing it's job!

Take 'er easy! 8O

And fix your throttle grip, it's not all the way up on the throttle thing! :P Wire brush the rust off the new brake lever.

~Adam

[8trackmind]

The grips are all the way on. They are just shorter than what came on there. It will get new ones someday.

The mirror problem...no problem at all. '80 and up mount on the clamp, not the master.


As far as the general state of dirt, rust and crap.
I still have to pull everything back apart to paint the fork legs, the master cyl and the calipers.
I went ahead and put it all together so:

1. I could test it.
2. So I could get all the pictures taken.

There are many threads that end with "I'll post pictures when I'm done and let everybody know how it went" only it never happens.
I didn't want My thread to end up the same way.

[Ninja_Lancer]

Shake down report:

I have not finished re-building My calipers (I may use a different type) but...it was 55 out today so I had to ride it! 8-[
I used the Katana Master cyl and One caliper.

If you decide you don't want to go to the trouble of doing this fork swap mod. Do yourself a favor, get a master cylinder off of a late model anything! While not exactly "sportbike" brakes by any means, the master cylinder alone made the single disk caliper feel much stronger.

The first two stops I made had me worried. There was a strange hissing sound coming from the rear. You guessed It...the rear tire was locking up because the front brake was finally doing it's job!

I can't wait 'till I get two on there. \\/

Nice Kaw there in the back. I'm glad it made it into at least one pic here. Since it's as close as I can get to it right now. Being in Mo. right now and headed for Iowa in the morning...... Now what that has to do with GS dual discs I have no idea..........

[8trackmind]

Now what that has to do with GS dual discs I have no idea..........

It's killing ya looking at my crappy photography, huh?

[Nerobro]

This is why I went with the 650 fork. Now there's two 1980 gs550e's with dual front disks.

I used the original 550 master cylinder too. (smaller piston.. more pressure)

[8trackmind]

This is why I went with the 650 fork. Now there's two 1980 gs550e's with dual front disks.

I used the original 550 master cylinder too. (smaller piston.. more pressure)

Post some photos. I'd like to see it.

[Nerobro]

*grins* I'm afraid I'll get smacked by frank for using images *grins*

I"ll get some shots of my fork tonight.

[ccratin]

Good stuff Jeff! Glad to see it came back together ok.

[8trackmind]

Thanks.
Maybe this will help the next poor sap that attempts it.

[8trackmind]

*grins* I'm afraid I'll get smacked by frank for using images *grins*

I"ll get some shots of my fork tonight.

Anyone else done this swap?
If so, let's see 'em.

[Ghostgs1]

Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray

[8trackmind]

Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray

Thanks!
The biggest problem I ran into with the 4 piston calipers was: I'm fighting a narrower triple tree just to get a regular caliper in there and they are too wide. (contact the wheel) They will fit over the disk as is but...if they had new pads...I don't know.
I'll make you a fantastic deal on 'em if you want to try you're hand at it. I'd love to see somone get some use out of them. PM Me.

[Mike_H]

Good Topic here 8track. I am currently in the process of performing the same swap on my 650L. I used the same forks you did (650E), so I changed the geometry slightly. I will have to get some pics taken. I have been cleaning and polishing along the way. I have the rotors mounted up, and the forks ready to go on the bike. BTW, I am using the master cylinder and calipers from another doner 650E. Didn't really think about using new stuff.

[Roger P.]

Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray

Here's a bit of inspiration for you:



I doubt the GS550 brakes are as reprehensible as those on the XJ turbo. These are R1 calipers attached with an adapter plate. These and some braided lines have transformed this particular bike (not mine) into a one finger tire howler. Rotors are also from an R1, which bolted up perfectly with no mods. Sorry about the pic size, not my site. I replaced my master cylinder with one from Parts N More designed for a dual disc XS1100 arrangement ($76 US). It has a larger 16.5mm piston than the original 13mm piston in the Turbo's master cylinder. Along with some Russell lines, these have transformed the brakes on my bike.

[Nerobro]

So yall wanted pictures right?


Here you can see my only "real" mod. There's 1/8" spacers in there.