Earlier Front Caliper Rebuild

[Guest]

I'm finally tackling rebuilding my front caliper and I've run into snags.

Its the earlier front caliper that looks like this...



The first thing I found was that the chamber in the caliper for the "holder" (#7) was filled with yellow dust. What is this stuff and how did it get in here? There is no apparent access to brake fluid in this chamber.

The "axles" (#11 and #12) had no grease on them whatsoever, are they supposed to?

Both boots (#3 and #5) were torn and need to be replaced, I can not find any source for the piston boot, if you have one or both, I'd like it.

I'm happy to say that the piston is beautiful, no pitting or anything and the piston seal had nothing behind it, no gunk, no corrosion, strange...

I'm thinking of writing a rebuild guide for this style of caliper because I couldn't find one on Cliff's site, is there any interest in that?

[Adler]

.......

[cowboyup3371]

Sorry Adler. I had that same one originally but got rid of them because I couldn't get the brake pads here locally. At the time I wasn't as big on buying from places like Z1 but I'm getting over that.

Have you called Z1 and seen if maybe they can get it?

[Adler]

Sorry Adler. I had that same one originally but got rid of them because I couldn't get the brake pads here locally. At the time I wasn't as big on buying from places like Z1 but I'm getting over that.

Have you called Z1 and seen if maybe they can get it?

I send them an e-mail, I assume they'll get back to me on Monday. To get rid of the older caliper is it as simple as getting a later one? Do they just bolt right up?

[cowboyup3371]

Mine did. I went from that to a 650 of I think 81 or so and it bolted right in. Course I found out afterwards I have 750 forks on my bike.

[Adler]

Intriguing, I'll keep that in mind if I can't get those boots.

[GS Jim]

CMS in Holland carries all the rubber parts for the rebuild of those calipers (I just did mine). Good service..... and they speak English.

http://www.cmsnl.com/

Pics of the rebuild

http://s654.photobucket.com/albums/uu264/Almuli/GS1000%20Front%20Brake%20Rebuild/?start=all

[rustybronco]

Both boots (#3 and #5) were torn and need to be replaced, I can not find any source for the piston boot, if you have one or both, I'd like it.

They still appear to be available new. have you tried ordering them?

if they aren't, we're both, Ummm... shall we say... what's that word?

[Adler]

CMS in Holland carries all the rubber parts for the rebuild of those calipers (I just did mine). Good service..... and they speak English.

http://www.cmsnl.com/

Pics of the rebuild

http://s654.photobucket.com/albums/u...ild/?start=all

Are you sure? Its not in their fische...

Thats a good rebuilt pictorial, you should get that published on BassCliff's site.

They still appear to be available new. have you tried ordering them?

if they aren't, we're both, Ummm... shall we say... what's that word?

I contacted 2 places (one of them is Z1) and only #5 seems to be available.

[GS Jim]

Are you sure? Its not in their fische...

Thats a good rebuilt pictorial, you should get that published on BassCliff's site.

Thanks, I sent a write-up to BassCliff and I believe he'll put it up when he gets a chance.

I just checked CMS's site, and they do have the parts for your rebuild available. I read somewhere your bike is the "L" model, correct? If so, go here: http://www.cmsnl.com/suzuki-gs1000-l...ist/95505.html

The parts are available and listed as such:

Part Number Description Price
3) 5911134020 O RING € 2.00
4) 5910734020 SEAL, PISTON € 4.00
5) 5910834020 BOOT, PISTON € 4.50
6) 5911234020 BOOT, HOLDER € 4.00

By the way, when I ordered my parts, they had all the rubber parts in stock, but not the front spindel I needed. This delayed shipment by 2 weeks. In hindsight, if I had ordered by phone, I could have asked them to ship the stuff they had in stock which would have allowed me to get a head start on the project. I would therefore recommend you order by phone and inquire if all you need is in stock or not.

When ordering, make SURE you have the right bike model (and country), as they carry parts for the same bikes over the entire range of models. For example the left side handle-bar switch assembly for the US spec 1980 GS1000S is unlike that of my 1980 German spec GS1000S.

And finally, their phone number is somewhat buried in their site, so here it is. From the 'States or Canada, dial 011 31-320-265120

The rest of their contact info is:
Address:
Artemisweg 245
8239 DD Lelystad
The Netherlands

Tel. : +31 (0) 320-265120
Fax : +31 (0) 320-268496
Business hours
Monday till Friday 09.00-12.30 13.00-17.00 CET
Closed on saturday, sunday & public holidays

Disclaimer: I'm not associated with CMS in any way, just a satisfied customer. FWIW, I've placed about half a dozen orders with them and never had a problem.

[Big T]

Hmm, my local dealer site says "Call for price"

You are replacing the O ring, right?

That yellow stuff is what happens when brake fluid doesn't get renewed

[Adler]

GS Jim;

Now that IS interesting. The page you sent me to is for the GS1000L, my model is a 550. The interesting part is that the boot looks the same! Anyone know if the caliper on a 1000 is bigger then a 550? Can the boot interchange???

Hmm, my local dealer site says "Call for price"

You are replacing the O ring, right?

That yellow stuff is what happens when brake fluid doesn't get renewed

There is no brake fluid in that chamber.

[BassCliff]

Hi,

Here ya go Mr. Adler...

79 GS1000S Front Brake Caliper Rebuild
by Mr. GS Jim (not 'GSJim')


Thank you for your induklgence,

BassCliff

[Big T]

There is no brake fluid in that chamber.

Exactly - I replaced my rear brake pads last year. While I was cleaning the caliper, I checked the piston (bad). Got a rebuild kit and opened the caliper - nothing but water and crystals in there.

It still worked

[GS Jim]

GS Jim;

Now that IS interesting. The page you sent me to is for the GS1000L, my model is a 550. The interesting part is that the boot looks the same! Anyone know if the caliper on a 1000 is bigger then a 550? Can the boot interchange???
.

Adler, did you try to navigate the CMS site ?? - it's quite easy. They have pretty much everything. Check the part numbers, but the calipers on the standard 77 - 79 and 1979 GS550L look to be the same as the those on my 1000


1979 GS550L

http://www.cmsnl.com/suzuki-gs550-l-1979-usa_model16032/partslist/93237.html

1977 -79 standard GS550

http://www.cmsnl.com/suzuki-gs550e-1977-1979-usa_model16028/partslist/92987.html

http://www.cmsnl.com/gs550e-1977-1979-usa_model16028/partslist/?q=gs550