Twinpot Brake upgrade on 78 Skunk

[salty_monk]

Few people asking for this.

Step by step would be:


1. Bolt rotor spacers to CBR rotors using 2x6mm bolts & nuts. Make sure central.
2. Drill the Suzuki bolt pattern using an 8mm or eq drill in a drill press.
3. Mount rotors on the wheel (spacer between the rotor & the hub) using original 6 x M8 Suzuki bolts each side. (check direction - rotors have arrows on them)
4. Mount the caliper bracket to the fork using the bottom bolt nearest the leg only (you need to find a nut & bolt for this, 8mm x 45mm if you put lock washer on outside of bracket, 8 x 40mm may be ok without the washer (for steel brackets only). Fine thread is best for "anti shake loose" if you can find it, use loctite too).
5. Cut 4mm off of the top of the speedo drive dust cover (looks like a "top hat" in profile, cut the top off of the hat). (Some older models don't need this as the cover is already short enough - usually bike with the riveted rotors as stock).
6. Mount the wheel back in the forks, tighten axle etc.
7. Mount the caliper to the top bolt
8. slide in the spacer for the bottom bolt & put that bolt in (Should be able to use stock bolts here - Steel brackets only)
9. Make sure all lines up & tighten to stock torque figures (use loctite).
10. Check clearances. The rotor rivets are usually closest point to the lower bolt. You should have 3mm plus each side & should be the same.
11. Bleed brakes
12. Check clearances & brake function (bike on jack so you can spin it).
13. Walk bike & check again
14. Ride it - take it easy till you're happy that everything is tight, clearances are good. Remember brakes need to bed in etc.

[salty_monk]

Have a few more sets if anyone is in need. Powdercoated black.

[salty_monk]

I'll PM you back. Depending on how quickly you want them I may be able to bring a set over in a couple of months... I'll be in the South East.

More brackets on the shelf if anyone needs them. $86 shipped in the US.

I'm looking for a set if you still have any. I have the CBR900 rotors, the twin pot calipers and they are going on a 78 GS1000HC. I live in the UK.

[salty_monk]

Remind me of the situation, bike, fork etc. The equation should be pretty simple - put the wheel on the axle with no spacers. Centre the rim between the fork legs. Measure between the bearing face & the fork leg on each side. That's the length of spacer you need on each side.

When you get the rim central the rotors should follow therefore you then have to work out how far they need to be offset to centralise between the pad area on the caliper. In theory that distance should be the spacer that I gave you but if it's not (because you are mix & matching from memory) then I might be able to see a way around it. I have some odd sizes from early experiments somewhere on the shelf.

Salty monk, thank you for your patience. I am trying to get my kit installed, but am having a very hard time getting everything to center. I would like to delete the speedo and am trying to use two mushroom spacers that are the same length... Still doesn't work! DO you or any others have any suggestions? If you need pics, just tell me what you want them of/what perspective.

[salty_monk]

I have used stock & I have used a couple of different ones from Kawasaki's. They are all similar. Stock was a little more wooden feeling from memory.

This is the one I am using now. Has mirror mount & adjustable lever - from an EX650

Hi all! Another upgrade installed to my GS1000G and it is working great! I had installed it sometime ago but got finally a change to go out for a test drive. I can't really compare it to the old brakes because I haven't driven with the bike that much, but it is a nice upgrade. I still need to take it to the inspector but it should be fine. Thank you Dan for the kit and all the help with it.

One question about the master cylinder. Are you using the stock master cylinder? Would it be good idea to upgrade it also?

[salty_monk]

Well we sorted that out... We now know how to fit them to the 85 550E! No change in parts but slightly different configuration.

I do have some more brackets here if anyone is in need.

[salty_monk]

I have PM'd you an email address for more pictures. It may well be something specific to that model - I am not sure anyone else has ever fitted to that particular one.

Sure we can figure it out though!

Are the pistons fully retracted & pads installed in the pictures?

You can use photobucket to post multiple pictures to a thread - there are other similar services (free) too.

Cheers,

Dan

Finally got around to putting the new rotors on and mounting the calibers and I ran into an issue. It looks like the rotor offset is at least 5mm too small.


The above picture shows the spacing when the rotor is up against the inside pad, I measured the gap between the spacer and bracket to be 5-6mm. If i try to tighten caliper mounting bolts any further it pulls strongly against the rotor. I don't know if I just messed up somewhere or if I need a greater offset for my bike. The bolts screwed into the caliper bracket are the original caliper bolts and the new bolt is an M8 by 45mm bolt as per your instructions in post #213. It seemed a little long when I was fitting it originally but then I realized those instructions where for the aluminum bracket which is thicker, it still clears the rotors though but i'll try to cut it down later.

My main question is, assuming I didn't make mistake somewhere can I add an additional spacer either on the hub or two spacers on the caliber mounting bolts? I can get custom spacers for the bolts pretty easily and if nessesary I can get a thicker hub spacer but I don't know if the final product would be strong enough.

I have several additional photos that might help clarify the issue, but I can't attach more than one per post. Let me know if I can supply any additional information.

Any help is greatly appreciated.

[salty_monk]

Send me an email/pm and we can work out if they're suitable. The GS hub is pretty narrow compared to the GSXR

Can I purchase spacers only and can you send to the uk.I am running a usd gsxr fork on an RG500 and want to fit a gs hub as I fancy spoked wheels.

[salty_monk]

You should be able to see it by eye, just centre it within the body of the caliper.
with the 550 Rotors it isn't precisely central but it doesn't seem to affect anything - as long as the pads don't drag on one side (because you are so far off centre the slide can't compensate) then you should be fine.

Check bu by hand before riding it!

Saltymonk, I know you must get tired of helping us all flounder through your upgrade! I am very happy with mine. I do want to ask for some measurement confirmations, though. The twin disk forks I got were a little narrow for some reason. I was wondering if you had some measurements to show how the rotor is to be centered in the calipers?