Brake Help Please

[Brianjonesphoto]

I really need some help with my front brake one my 83 550E. I don't think I'm getting much brake power. I'm having issues with lever travel. I can pull the lever all the way to the grip without the wheel locking or starting to feel like it is going to lock up.

I'm a total noob to motor cycles, but I've done a fair amount of brake work.

So far this is what I've done

Rebuilt calipers with new OEM seals
New rubber brake lines went to 2 lines instead of 3
New EBC HH pads
Rebuilt Stock Master
02 Katana Master

I got this set up working as best I could then upon closer inspection I found what I though was the answer. A large pit in the bore of the Master. I have since replaced the master with one from an 02 katana. I rode it today and the brakes feel better I'm getting lots of brake dive when I grab the lever, but I can still bottom the lever to the grip. This isn't a great feeling. Grab as much brake as you can and wiat for the bike to slow down.

I'm pretty sure I've got all of the air out of the lines. I've run lots of fluid through, bled the m/c at the banjo. I'm no longer getting air out of the lines. There lever doesn't really have any pump up si I don't think it's air.

Any ideas?

Thanks

[ifly85]

I may be misunderstanding where you bled the lines, but on all of the brakes I have seen on GS bikes, there is a bleeder on the caliper. That is the end of the line, so if you bleed somewhere upstream from there, then you would still have air in the line.

Also, you may be able to adjust the brake lever with the screw adjustment at the lever.

Good luck.

[Brianjonesphoto]

I've bled the system from the calipers, but I also have read posts about bleeding the m/c first at the bandjo to get all of the air out, then work down stream.

I do have the lever in the #1 position, the most reach.

[Dink]

Take your original m/cylinder to a brake specialist and have it sleeved. sounds like the GSX-f master is the wrong bore or not a long enough stroke.
Make sure you let the brake specialist know there is a brand new kit in the master cylinder, so they dont throw them out and charge you for a new one again.

Dink

[Brianjonesphoto]

Take your original m/cylinder to a brake specialist and have it sleeved. sounds like the GSX-f master is the wrong bore or not a long enough stroke.

Dink you are right There is not enough stroke into m/c and it's a 14mm bore instead of 5/8. I think I've found a work around though. Since it's an adjustable reach lever I shimmed the gap between the pin and the adjuster to in effect give me a larger reach. This has given me about 10mm more stroke. Now I'm hitting the engagement point at 1/2 lever travel instead of 3/4. Just went for a test ride plenty of stopping power. Grabbing a handfull of front brake unwieghts the rear to the point of you feel the seat drop when you get to a full stop. I should have lots of stop with the pads bed in.

I know the shim thing isn't the best idea since there is a chance they could vibrate loose on the road. I've figured out a way to make an adjustable pin. I drove the original pin out and tapped the shote for a 1/4-20x3/4 set screw. With a little filing It is an adjust able pin. Now I still have the reach adjustment and a longer lever through.

Thanks for the help.