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Ok, this has already been in two threads, but I wanted to put all the info in one place so it'll be easier for everyone to find in the future.
This is all the information you need to swap a GS over to dual piston calipers. The calipers and rotors used for this swap are cheap, and easy to find. The mounting brackets are inexpensive and well engineered. Best of all, it really works, and doesn't change the look of the bike. I've been running this set up for almost two years with my homemade prototype brackets and haven't had a moments trouble. The bike stops hard with no drama from any speed. I've clamped down on mine from as fast as 100mph and the bike simply stops.
While I originally came up with the idea of doing this, fellow GS'r Saltymonk has come up with the trick brackets. If you want a set, contact him. They are well made and look great on the bike.
The parts:
EX 250 Ninja 1988 to 2007 (single caliper on right side)
EX 500 Ninja 1994 to 2007 (single caliper on right side)
ZL 600 B1 Eliminator 1995 to 1996
ZR 550 B1/B2/B3
Zephyr 1990 1992 1993 ZX 600 C1-C9
Ninja 600 R 1988 to 1996
ZR 750 C1/C2/C3 1991 to 1993
ZX 750 F1/F2/F3/F4 Ninja 1987 to 1990
ZG 1000 A9-A20 Concours 1994 to 2006
ZX 1000 B1/B2/B3 Ninja ZX10 1988 to 1990
Suzuki also used this caliper on the VX800, GS500 as a single and the GSX1100G as a dual.
If you decide to follow me down this path, you do so at YOUR OWN RISK. This thread is for entertainment only.
This is my 1978 GS1000 with the mod. In these photo's I'm still running my homemade prototype steel brackets. Again, contact Saltymonk is you want a set of his trick aluminum brackets.
Here's more info from Dan:
This is all the information you need to swap a GS over to dual piston calipers. The calipers and rotors used for this swap are cheap, and easy to find. The mounting brackets are inexpensive and well engineered. Best of all, it really works, and doesn't change the look of the bike. I've been running this set up for almost two years with my homemade prototype brackets and haven't had a moments trouble. The bike stops hard with no drama from any speed. I've clamped down on mine from as fast as 100mph and the bike simply stops.
While I originally came up with the idea of doing this, fellow GS'r Saltymonk has come up with the trick brackets. If you want a set, contact him. They are well made and look great on the bike.
The parts:
- I used 1978 GS1000 forks, but this should work on the GS1100E, GS850G GS750E etc.
- Pair of 300mm rotors from a Single disk bike 550 or larger. The rotors you want are off of the 78 GS1000C, 79 GS1000N, 78 GS750C, 79GS750N or the 78,79,80 GS550. The 550 rotors will be the easiest to find because they ALL had them. The bikes with dual rotors (and the 450 and smaller bikes) have 270mm rotors. They will not work on this swap.
- Two trick aluminum brackets. (PM Saltymonk if you want a pair)
- Pair of dual piston slider calipers. This caliper mostly came on Kawasaki's, but was also used on the big and heavy '91 '92GS1100G. This is the list of the Kawasaki models that used this caliper:
EX 250 Ninja 1988 to 2007 (single caliper on right side)
EX 500 Ninja 1994 to 2007 (single caliper on right side)
ZL 600 B1 Eliminator 1995 to 1996
ZR 550 B1/B2/B3
Zephyr 1990 1992 1993 ZX 600 C1-C9
Ninja 600 R 1988 to 1996
ZR 750 C1/C2/C3 1991 to 1993
ZX 750 F1/F2/F3/F4 Ninja 1987 to 1990
ZG 1000 A9-A20 Concours 1994 to 2006
ZX 1000 B1/B2/B3 Ninja ZX10 1988 to 1990
Suzuki also used this caliper on the VX800, GS500 as a single and the GSX1100G as a dual.
If you decide to follow me down this path, you do so at YOUR OWN RISK. This thread is for entertainment only.
This is my 1978 GS1000 with the mod. In these photo's I'm still running my homemade prototype steel brackets. Again, contact Saltymonk is you want a set of his trick aluminum brackets.
Here's more info from Dan:
Originally posted by salty_monk
View Post
So following on from 8tracks post http://www.thegsresources.com/_forum...ad.php?t=98098 I have developed a set of brackets to be used with these late 80's early 90's twinpots & the GS550 larger rotor.
I was trying to find a modern rotor that would also work but no joy as yet, the closest is a rare Honda beast but in the end the rotor turned out to be just a few mm too big! Still searching.
Anyway, see below pics (ignore "temporary bolts" & washer stacks) I need to find a source of decent 45mm fine thread 10mm x 1.25mm bolts. Stock are 40mm & whilst you could use them with threadlock I wanted to go on the side of caution. I didn't cut these as I find fine thread is a pain to put a "lead" on but I will if I have to.
The bracket & spacer is Aluminium or Aluminum for those that speak American
The bracket is 8mm thick & this one has been powder coated silver as it was what the factory was running & easier than polishing. They could be powder black or raw or even polished but they do have to be all the same (sorry I sound like Henry Ford!)
These have enough tolerance in them (I believe) to allow for any minor manufacturing tolerances that Suzuki may have had but without compromising strength.
I could have had a fancy triangulated pattern put in them but I figured the minimal weight saving wasn't worth the extra cost.
This conversion cost around 50 bucks (2 disks from Ebay & a set of calipers). The Suzuki dual piston MC works fine with them, it's the same 5/8" bore as the Kawasaki one that comes with these brakes.
The brackets use a spacer as to make them 1 piece billet is not economical for manufacture, it would double the price at least, probably treble it for no performance & minimal "bling" gain (it's hidden after all). The bracket is also Aluminium.
This is on my new skunk so first test ride will be this week but I posted here in anticipation of a trip I am making in a couple of weeks... I could bring some back to save the freight.
The good news is that total cost should be around $20 per side plus shipping ($40 total plus shipping).
Bad news is I need a reasonable qty (say 50 - 100 sets) & to transport them myself to get this price.
PJ, if you could help me put this one OLDSKOOL that would be great, I have a friend coming in July who can transport to GB or USPS post is not that expensive (& $40 in ££ is about less than a good curry right now).
I can supply these, what you do with them is your business, I make no claims that they are road legal, in any way DOT tested or anything else.
I'm not looking to make a lot of money from this, 8track will get a set at cost or less for doing the initial work & I can honestly take it or leave it. I have a couple of sets for my bikes already.....
Far superior brakes, bolt on, with minimal hassle for less than 100 bucks! (Many modern enduro & cruiser type bikes use very similar calipers to this but SINGLE SIDED! They should be good!
Let me know what you think......
Dan
I was trying to find a modern rotor that would also work but no joy as yet, the closest is a rare Honda beast but in the end the rotor turned out to be just a few mm too big! Still searching.
Anyway, see below pics (ignore "temporary bolts" & washer stacks) I need to find a source of decent 45mm fine thread 10mm x 1.25mm bolts. Stock are 40mm & whilst you could use them with threadlock I wanted to go on the side of caution. I didn't cut these as I find fine thread is a pain to put a "lead" on but I will if I have to.
The bracket & spacer is Aluminium or Aluminum for those that speak American
The bracket is 8mm thick & this one has been powder coated silver as it was what the factory was running & easier than polishing. They could be powder black or raw or even polished but they do have to be all the same (sorry I sound like Henry Ford!)
These have enough tolerance in them (I believe) to allow for any minor manufacturing tolerances that Suzuki may have had but without compromising strength.
I could have had a fancy triangulated pattern put in them but I figured the minimal weight saving wasn't worth the extra cost.
This conversion cost around 50 bucks (2 disks from Ebay & a set of calipers). The Suzuki dual piston MC works fine with them, it's the same 5/8" bore as the Kawasaki one that comes with these brakes.
The brackets use a spacer as to make them 1 piece billet is not economical for manufacture, it would double the price at least, probably treble it for no performance & minimal "bling" gain (it's hidden after all). The bracket is also Aluminium.
This is on my new skunk so first test ride will be this week but I posted here in anticipation of a trip I am making in a couple of weeks... I could bring some back to save the freight.
The good news is that total cost should be around $20 per side plus shipping ($40 total plus shipping).
Bad news is I need a reasonable qty (say 50 - 100 sets) & to transport them myself to get this price.
PJ, if you could help me put this one OLDSKOOL that would be great, I have a friend coming in July who can transport to GB or USPS post is not that expensive (& $40 in ££ is about less than a good curry right now).
I can supply these, what you do with them is your business, I make no claims that they are road legal, in any way DOT tested or anything else.
I'm not looking to make a lot of money from this, 8track will get a set at cost or less for doing the initial work & I can honestly take it or leave it. I have a couple of sets for my bikes already.....
Far superior brakes, bolt on, with minimal hassle for less than 100 bucks! (Many modern enduro & cruiser type bikes use very similar calipers to this but SINGLE SIDED! They should be good!
Let me know what you think......
Dan
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