82 850GL Resto...here we go

[GateKeeper]

Nice assortment of parts you got there, your getting along just nicely and soon it will be all over.....

Hey since you have the cluster all apart and are changing bulbs and what not, did you think about using LED bulbs as replacements.....?

are you sure you have enough crush washers ? for the new brake lines....or I just can't see how many are in each package...

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[Good Times]

Nice assortment of parts you got there, your getting along just nicely and soon it will be all over.....

Hey since you have the cluster all apart and are changing bulbs and what not, did you think about using LED bulbs as replacements.....?

are you sure you have enough crush washers ? for the new brake lines....or I just can't see how many are in each package...

.

Thanks GK, you are my 300th post! Wish I had a prize for you, but I spent all of my money on my bike.

I'm looking forward to getting everything on the brakes. I need to get the calipers painted and bolts cleaned up. Who knows, I may even get some of those fancy Zinc or Stainless Allen Head Socket bolt thingies I've seen other guys use.

I kept everything together until I got my new lines. Wanted to make sure they matched up before I took everything apart.

Didn't think about LED bulbs. Not a bad thought though. I have 20 crush washers. I ordered over the phone with Bakes at Z1. He said I needed two packs of ten.

Can't wait to see your tins. I'll be taking mine in before too much longer. I'm going to wait until after I tune the carbs to get my header ceramic coated.

[JimmyR]

At the risk of sounding like an endorser of powder coat products (!) I can recommend texture black powder coat for the brake calipers. The texture helps hide any little dents you might have got over the years and it's VERY tough stuff. I used texture black on mine with new bolts - the stock colours are black for the calipers and chrome for the attachments to the forks, and they look amazing IMHO.

Then I also used Metal Gear pads and discs and the whole thing looks better than brand new, and seems to stop pretty well too.

[Good Times]

Thanks JimmyR.

I spent a little time to night disassembling the front left caliper. It looks pretty good. The piston is in good shape and it all cleaned up nicely. I'll let it dry out and then hit it with some paint. I'll also pick up some allen head bolts from Fastenal for the calipers as well. The seals are good. I was glad to see that.







I'm hoping that this broken bleeder on the rear caliper won't be a problem.



I've got two more bleeders on order but will probably wind up replacing them all.

The dynojet kit should be in on Wednesday.

[GateKeeper]

Looking good there GT......

just replace the bleeder screws, and you won't have to worry about them...piston looks good, are you changing the seals, or are they still on good shape ?

some paint, new SS bolts, and they will look like a million bucks

we are close to the finish line.....

[JimmyR]

Your brakes look in rather better nick than mine were. The pistons look pristine! I ended up replacing the bolts, boots and bleeders. So I guess the only original parts are the calipers.

[Good Times]

Looking good there GT......

just replace the bleeder screws, and you won't have to worry about them...piston looks good, are you changing the seals, or are they still on good shape ?

some paint, new SS bolts, and they will look like a million bucks

we are close to the finish line.....

I can see the light at the end of the tunnel.

I'm thinking the same thing on the bleeders. The seals are still in good shape so I'm not changing those. Well, this one is good anyway. We'll see about the others.

Your brakes look in rather better nick than mine were. The pistons look pristine! I ended up replacing the bolts, boots and bleeders. So I guess the only original parts are the calipers.

Jimmy I was very pleased with how the internals looked. Didn't want to replace pistons.

[JimmyR]

Actually on my bike the pistons weren't so bad, at least on the front calipers. But the bores were scary. Yours look perfect.

BTW I found putting the seals on the pistons really difficult until a guy at the Suzuki store showed me how to do it. Once you know how to do it it's really easy, but unless someone shows you it's really hard! Difficult to explain too.

[Good Times]

Hey Jimmy, this is what I am going to do. Use the good ol' air compressor.

http://www.youtube.com/watch?v=-ZiJ3a7Gev4

[GateKeeper]

Hey Jimmy, this is what I am going to do. Use the good ol' air compressor.

http://www.youtube.com/watch?v=-ZiJ3a7Gev4

Ohhhh my.......that was funny as hell.......

[Missile99]

Cool GT. It's nice to see you approaching the finish line. I plan on rebuilding my brakes next month and will definitely try that little trick.

Ohhhh my.......that was funny as hell.......

Yes indeed. How simple and great ingenuity.

[Daffid]

Lol! Great video, that little trick is going to be quite handy here in a couple of months. I hadn't even thought that far in advance on how I was going to tackle that. I do know that one of the calipers on the front end is seized up.

[Good Times]

I used the air compressor to very easily pop the piston out and just thought I would reverse the process when I put it back in. Just happened to find a video where some one else had done the same.

[Good Times]

Had another goodie show up today. The DJ Stage 3 Kit.



But.....I'm out of town all next week so the build is postponed again. The trip is worth it though.

Anyone up for some King Salmon and Halibut?

See ya in a about a week!

[Good Times]

Rear Caliper

Well, that bleeder on the read inside piston proved to be a problem. I hit it with heat for a few cycles. Knocked the mess out of it with a hammer to loosen it up. Nothin doing. All attempts to work it free were failing.

So I drilled and tapped it. Did not work. The bleeder won't seat correctly now and leaks. Time to find a used rear caliper.

The front calipers and coming along nicely. Painted them up and have put the back together. I'll post some pics next time.

May try to find a good disc while I'm at it.