front master cylinder rebuild problems

[greg78gs750]

Hi all,

hopefully someone can give me some clarity. i am reassembling the front m/c on my 1100 es and the dust boot seems to be wrong? this is from the suzuki rebuild kit, the rubber dust boot is just way too big to fit in the bore of the m/c.
here is the boot sitting on top of the m/c. you can see it is too big to go down in there.


here it is, inverted


also, what is the thin shim for? there was no such thing on disassembly:


this is a bit frustrating, brakes is all i need to be riding again... thanks all!!

greg

[greg78gs750]

sheesh, looking at this some more, this is just not right. i am used to replacement parts being a little different, but something is just not right here. pics to follow.

[greg78gs750]

old and new, new on left. very different design


side view of the plungers


then there is this little dude, that DOES NOT fit in the bore of the m/c at all:


part number on the "cup set master" is correct according to the fische, 59600-49830. i am stumped, any help would be great.

[Nessism]

The shim should be there. It goes between the plunger and the spring with the rubber hat piece.

The boot tucks inside the ID of bore and lays in a groove. Of course, this assumes you have the proper master cylinder kit.

EDIT: photos above showed up while I was typing. Think you have the wrong kit. Can you post a photo showing the bore area of the master cylinder?

[greg78gs750]

here you go. i, too, am thinking it is the wrong part, but the # on the bag matches the fische...

[Nessism]

Pretty sure that's the wrong kit. The masters that take that other kit have a boot groove down into the upper bore area, the likes of which I can't see in your photos.

[greg78gs750]

hm. F@#!. waiting on parts again. if anyone can hip me to what might be the correct part number for this, that would be great. it is obviously not the one i have. i gotta go to bed now or i'm going to break something, heh. thanks for the eyes, nessism.

greg

[Big T]

Pretty sure that's the wrong kit. The masters that take that other kit have a boot groove down into the upper bore area, the likes of which I can't see in your photos.

Ed,

Are you sure? It looks to me as if the boot groove is the shiny circle and the circlip groove is a dark circle in those photos

[greg78gs750]

big t, i am pretty sure. that boot does not fit sown there, and the little square/circle thing doesnt fint in the cylinder bore at all. i need to figure out what the right part # is so i can get one ordered quick. the fische are little help, the detail in the cup set is....lacking a bit. i'll do some investigation later and give some links, someone here is going to be able to help me (praying emoticaon)

greg

[Nessism]

The kit as shown is the same one as the 1980 GS1000S uses. That steel round plug, with O-ring, piece presses down into the bore (light press fit) and is then held with a circlip. The boot lip fits into a groove in the bore. Hard to tell for sure from those photos, but I can't see the appropriate details in the master cylinder bore to accommodate these parts. Also, obviously, the kit is different from what came with the master. The old kit looks to be a common Suzuki kit, as installed on a bunch of other bikes. I think this is the needed part number but can't promise on that...Part# 59600-45831

[greg78gs750]

so, it appears the parts diagrams/fische are, in fact, wrong. i checked babbitts and alphasports and they both list the -49830 part for both the 1100 e and esd. The correct number appears to be 59600-45831. the diagram shows the correct part, just the # is wrong. For contrast, the diagram for the "s" is correct, with the correct part number with it. Thanks for pointing me in the right direction, ed.

Incidentally, i have a front master cylinder piston and cup set, brand new, fits the 83 katana 1100, for sale! 50 bucks shipped, what a deal!

what a pain in the drain. maybe i should let suzuki know their fische are wrong? chances are they probably don't care....

thanks again!

greg