82 650E - Alternative/Upgrade brake options?

[KillerGriller]

Hi all,

I've been rebuilding an '82 650E that's sat for way too long, it's going well but I have a rear brake setup that's giving me issues. After dismantling the caliper, cleaning it, and changing the seals, the caliper will compress but not release when the brake lever is pressed and released. I was told that it was likely dirt in the master cylinder and so I pulled it and cleaned it out, remounted it and ran into similar issues. Since then I've pulled it all out again and done a VERY thorough cleaning/inspection, pulled apart the entire MC (can't remember if I did the full deal last time or not) and I'm ready to reassemble/remount, hopefully it works this time.

IF this doesn't work, and I have to buy some replacement parts, I was curious about alternate setups that fit/work with our bikes? Aside from bolt holes/clearance issues can newer break setups be used on our bikes? e.g. - there's a 2007 FZR being parted out near me with brakes being offered (mc, lines, caliper pads,), if you could mount it and there was clearance are there issues using something like this? Or are there bikes that are bolt on fits? Or just aftermarket setups that are worth the upgrade?

Thanks for any insight you guys can provide, just looking at options right now

[Nessism]

Did you make sure the tiny little fluid return hole in the master is open? That hole often plugs up and causes to brakes to not release. Also, it's critical that you change the brake lines because they are likely full of crud which will contaminate the system quickly and set you back to the beginning.

[KillerGriller]

Did you make sure the tiny little fluid return hole in the master is open? That hole often plugs up and causes to brakes to not release. Also, it's critical that you change the brake lines because they are likely full of crud which will contaminate the system quickly and set you back to the beginning.

Yes, I made a point to look at that hole, you’re right it’s tiny.

Also, I put on new lines braided lines front & back

[tom203]

If you can’t save your existing master cylinder....there’s a few that would work as direct swap

• 1982 GS1100E,ES - REAR MASTER CYLINDER
• 1982 SUZUKI GS1100EZ & GS1100ESZ - REAR MASTER CYLINDER
• 1982 SUZUKI GS650EZ - REAR MASTER CYLINDER
• 1982 SUZUKI GS750EZ - REAR MASTER CYLINDER
• 1983 GS1100E & ES - REAR MASTER CYLINDER
• 1983 SUZUKI GS1100ED & GS1100ESD - REAR MASTER CYLINDER

[cowboyup3371]

Also, check out Salty Monk's upgrade here - https://www.thegsresources.com/_foru...hlight=twinpot

[KillerGriller]

I cleaned all the parts and remounted them this weekend, but haven't had a chance to properly test them yet, Hopefully soon.

Also, check out Salty Monk's upgrade here - https://www.thegsresources.com/_foru...hlight=twinpot

Will do, have it open now

If you can’t save your existing master cylinder....there’s a few that would work as direct swap

• 1982 GS1100E,ES - REAR MASTER CYLINDER
• 1982 SUZUKI GS1100EZ & GS1100ESZ - REAR MASTER CYLINDER
• 1982 SUZUKI GS650EZ - REAR MASTER CYLINDER
• 1982 SUZUKI GS750EZ - REAR MASTER CYLINDER
• 1983 GS1100E & ES - REAR MASTER CYLINDER
• 1983 SUZUKI GS1100ED & GS1100ESD - REAR MASTER CYLINDER

I'll keep those in mind when/if I'm part surfing.

Are there other, modern bikes that have swappable systems? (even if you have to fab up a mounting bracket?)

Thanks for all the feedback folks!