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PostPosted: Thu Sep 13, 2018 7:11 pm 
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Around the block

Joined: Wed Aug 22, 2018 10:55 pm
Posts: 60
Country: USA
Bikes owned: GT100, GT500
1975 GT500:

How to repair or restore front brake system?

My goal is to make the brake system work properly and reasonably clean.
( It does not have to be perfect looking, at least for now)

Bike came with extra brake system ( partial ), which includes broken master cylinder and
the pipe/cable.

In addition, the is brake system on the bike which is not working.

I need to decide which one to work on?
How to decide which one to work on?
( Attached some pics below)

Once that is decided, I need to know:

1. Where do I start?
2. Which parts of brake system to replace?
3. How should I proceed in terms of what tasks are to be performed?

Appreciate all/any help.


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PostPosted: Thu Sep 13, 2018 7:13 pm 
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Around the block

Joined: Wed Aug 22, 2018 10:55 pm
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Country: USA
Bikes owned: GT100, GT500
More pics..


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PostPosted: Fri Sep 14, 2018 9:38 am 
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Joined: Mon Dec 01, 2008 2:52 am
Posts: 1159
Location: Manchester, UK
You can easily restore the caliper - the seals and pistons are still available from Suzuki for rebuilds.

For the master cylinder, I wouldn't bother trying to restore what you have. It's fiddly and the working bore of the m/c is probably screwed with corrosion.

Just buy a used Suzi m/c from eBay. On my GT380 (same brake set up as the GT500) I fitted a good used m/c from a Suzi RF600 (Suzi used the same type on loads of different bikes, from the Bandit to the GS500 etc etc). The black all-metal m/c body looked fine on the bike and the larger internal piston made the brake much more effective.

_________________
1976 GT380 - wounded by me, and sold on
2006 SV650S. It's got cams, and valves, and stuff


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PostPosted: Sat Sep 15, 2018 8:35 am 
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Around the block

Joined: Wed Aug 22, 2018 10:55 pm
Posts: 60
Country: USA
Bikes owned: GT100, GT500
Craig380 wrote:
You can easily restore the caliper - the seals and pistons are still available from Suzuki for rebuilds.

For the master cylinder, I wouldn't bother trying to restore what you have. It's fiddly and the working bore of the m/c is probably screwed with corrosion.

Just buy a used Suzi m/c from eBay. On my GT380 (same brake set up as the GT500) I fitted a good used m/c from a Suzi RF600 (Suzi used the same type on loads of different bikes, from the Bandit to the GS500 etc etc). The black all-metal m/c body looked fine on the bike and the larger internal piston made the brake much more effective.


Great!

Will work along these lines..Thanks a lot for your input!

Appreciate it.

What about the brake line?
Will it need a good cleaning from inside/outside?
I would think it will be good idea to clean it inside, correct?

How do I clean it from inside?
What cleaner should I be using?
Can I just use any parts cleaner like WD40?


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PostPosted: Sat Sep 15, 2018 8:51 am 
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Around the block

Joined: Wed Aug 22, 2018 10:55 pm
Posts: 60
Country: USA
Bikes owned: GT100, GT500
Craig380 wrote:
You can easily restore the caliper - the seals and pistons are still available from Suzuki for rebuilds.

For the master cylinder, I wouldn't bother trying to restore what you have. It's fiddly and the working bore of the m/c is probably screwed with corrosion.

Just buy a used Suzi m/c from eBay. On my GT380 (same brake set up as the GT500) I fitted a good used m/c from a Suzi RF600 (Suzi used the same type on loads of different bikes, from the Bandit to the GS500 etc etc). The black all-metal m/c body looked fine on the bike and the larger internal piston made the brake much more effective.


Could not find a used m/c on ebay.
Found a new m/c on eBay.

https://www.ebay.com/itm/Suzuki-GS500-G ... 4085!US!-1

Will this need modification to brake line ?
( Not that mind any modification if needed, just want to make sure that it is doable with relatively ease )

Will this be a good choice?

Thanks.


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PostPosted: Sat Sep 15, 2018 9:34 am 
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Joined: Mon Dec 01, 2008 2:52 am
Posts: 1159
Location: Manchester, UK
I can't say if that m/c is a good choice or not, as it is a pattern part and not genuine Suzi, but it's not expensive.

I would definitely not re-use the old brake line: simply purchase a new stainless steel braided hose with banjo fittings at both ends from a bike shop, and fit it using new copper washers. The best stuff for cleaning up the caliper bore and seal grooves etc is proper brake cleaner, which leaves no residue. It's dirt cheap.

Clean out the seal groove really carefully as it will no doubt be full of white furry corrosion. A Dremel with a soft wire brush is ideal.

_________________
1976 GT380 - wounded by me, and sold on
2006 SV650S. It's got cams, and valves, and stuff


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PostPosted: Sat Sep 15, 2018 9:48 am 
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To the on ramp
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Joined: Mon Jun 12, 2017 12:01 pm
Posts: 222
Location: Galveston County, Tx.
Country: USA
Bikes owned: '75 T500M since '93 Ridden it over 100,000 mi
GT500-2stroke wrote:
.......What about the brake line?
Will it need a good cleaning from inside/outside?
I would think it will be good idea to clean it inside, correct?
How do I clean it from inside?
What cleaner should I be using?
Can I just use any parts cleaner like WD40?

God forbid, you might kill a pedestrian, yourself and/or a passenger with thinking like that. That brake line may be 40+ years old.

From your pic, it looks like it may have already been leaking at one time.

Go with the the upgrade of a new stainless steel braided line as suggested.

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PostPosted: Mon Sep 17, 2018 6:01 am 
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I likes them jubblies
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Joined: Wed Oct 15, 2008 11:19 am
Posts: 2272
Location: OL BLIGHTY uk
Country: uk
Bikes owned: tracer 700
I remember someone years ago fitted a brembo caliper off an MZ motorcycle.
and they claimed it work a hell of a lot better.
I did own an MZ and I can tell you these do work brilliantly.

Image

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working with the mentally retarded I would
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PostPosted: Mon Sep 17, 2018 2:25 pm 
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Road race school

Joined: Wed Jul 10, 2013 12:04 pm
Posts: 829
Country: England, UK
Bikes owned: FZ50, GP100, RG125 Gamma, GT380, Bandit 1200S
Craig380 wrote:
I would definitely not re-use the old brake line: simply purchase a new stainless steel braided hose with banjo fittings at both ends from a bike shop, and fit it using new copper washers.

+1 on that. Stainless braided hoses aren't too expensive and can make a huge difference. They will usually fit a majority of master cylinders, so should be fine with your new later model m/c.
I also agree that a modern replacement caliper would also be a worthwhile addition. I got one off an old GS750 to fit my GT380, but with a Salty-monk adaptor you could fit something much better and more modern if you can afford it.


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PostPosted: Mon Sep 17, 2018 6:11 pm 
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Moto GP
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Joined: Mon Dec 13, 2010 4:32 pm
Posts: 3256
Location: southwestern Pennsylvania
Country: USA
Bikes owned: 69 T350 thru 75 GT750
The salty-monk upgrade requires a slightly larger brake disk.
For the GT250/GT380 you need to use a disk that’s for a GT500/GT550/GT750. On our GT250 cafe build we used an EBC VMD disk that they sell for the GT750.

For a GT500/GT550/GT750 you need to use a disk that’s larger than any that Suzuki used. On our T500 cafe build we are using an EBC disk that they sell for an obscure Honda — we haven’t gotten very far on this project so the results are TBD.

_________________
BAS (Bike Acquisition Syndrome) - too many bikes but have room for more

Suzuki:
GT750 2x75
GT550 72 project & 75
GT380 72
T500 73 project
T350 69, 71 & 72 project
T250 72
Honda 85 CB650SC & 86 CB700SC
09 Triumph Bonneville SE


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PostPosted: Sat Sep 22, 2018 9:55 am 
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Around the block

Joined: Wed Aug 22, 2018 10:55 pm
Posts: 60
Country: USA
Bikes owned: GT100, GT500
Craig380 wrote:
I can't say if that m/c is a good choice or not, as it is a pattern part and not genuine Suzi, but it's not expensive.

I would definitely not re-use the old brake line: simply purchase a new stainless steel braided hose with banjo fittings at both ends from a bike shop, and fit it using new copper washers. The best stuff for cleaning up the caliper bore and seal grooves etc is proper brake cleaner, which leaves no residue. It's dirt cheap.

Clean out the seal groove really carefully as it will no doubt be full of white furry corrosion. A Dremel with a soft wire brush is ideal.


Before I purchase, just want to make sure.

Found one on eBay. This should work for me, right?
Where do I get copper washers from?
You mean any bike/hardware store?

Could you please have a look at this and confirm.

https://www.ebay.com/itm/60cm-90cm-120c ... 0005.m1851


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PostPosted: Sat Sep 22, 2018 10:46 am 
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Expert racer

Joined: Mon Dec 01, 2008 2:52 am
Posts: 1159
Location: Manchester, UK
That's the right type of line, make sure the fittings (banjo and securing nut) are stainless steel too. On cheap hoses they can be alloy, which is not strong enough for brake systems. Any bike shop should sell packs of the copper washers.

_________________
1976 GT380 - wounded by me, and sold on
2006 SV650S. It's got cams, and valves, and stuff


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