• Required reading for all forum users!!!

    Welcome!
    Register to access the full functionality of the GSResources forum. Until you register and activate your account you will not have full forum access, nor will you be able to post or reply to messages.

    A note to new registrants...
    All new forum registrations must be activated via email before you have full access to the forum.

    A Special Note about Email accounts!
    DO NOT SIGN UP USING hotmail, outlook, gmx, sbcglobal, att, bellsouth or email.com. They delete our forum signup emails.

    A note to old forum members...
    I receive numerous requests from people who can no longer log in because their accounts were deleted. As mentioned in the forum FAQ, user accounts are deleted if you haven't logged in for the past 6 months. If you can't log in, then create a new forum account. If you don't get an error message, then check your email account for an activation message. If you get a message stating that the email address is already in use, then your account still exists so follow the instructions in the forum FAQ for resetting your password.

    Have you forgotten your password or have a new email address? Then read the forum FAQ for details on how to reset it.

    Any email requests for "can't log in anymore" problems or "lost my password" problems will be deleted. Read the forum FAQ and follow the instructions there - that's what we have one for...

  • Returning Visitors

    If you are a returning visitor who never received your confirmation email, then odds are your email provider is blockinig emails from our server. The only thing that can be done to get around this is you will have to try creating another forum account using an email address from another domain.

    If you are a returning visitor to the forum and can't log in using your old forum name and password but used to be able to then chances are your account is deleted. Purges of the databases are done regularly. You will have to create a new forum account and you should be all set.

GS1000 Ninja Brake mod w/ pics

  • Thread starter Thread starter 8trackmind
  • Start date Start date
8

8trackmind

Guest
Again, for those thinking of doing this swap, read this thread carefully. Ask questions. Understand what you're doing BEFORE you start.
So far, this swap has only been done on 1978 GS1000's.
If you are attempting this on another type of GS, ask me, I may be able to help you figure it out for your model.

It only works if you use fork legs from a dual disk bike.
Rotors from a single disk bike.
And the correct calipers.

It's that simple. If you don't understand how, or why it works, read it again, ask questions or don't attempt it.



The parts I used:
  1. 1978 GS1000E forks. The fork lowers MUST BE FROM A DUAL DISK BIKE
  2. Pair of rotors from a Single disk bike 550 or larger. Any year should work, but 78, to 80 are what I used. 78 1000C 791000N 78,79 GS750 78,79,80 GS550
  3. Pair of 1990 something Kawasaki Ninja twin piston calipers. See list below for the correct calipers.
  4. Two custom made lower brackets. (made by me) EDIT: These were the prototypes. If you want the real deal, send a message to salty monk Here's the thread: Link
  5. If you decide to follow me down this path, you do so at YOUR OWN RISK. This thread is for entertainment only.


This is the list of the Kawasaki models that used the correct caliper for this swap.

EX 250 Ninja 1988 to 2007 (single caliper on right side)
EX 500 Ninja 1994 to 2007 (single caliper on right side)
ZL 600 B1 Eliminator 1995 to 1996
ZR 550 B1/B2/B3 Zephyr 1990 1992 1993
ZX 600 C1-C9 Ninja 600 R 1988 to 1996
ZR 750 C1/C2/C3 1991 to 1993
ZX 750 F1/F2/F3/F4 Ninja 1987 to 1990
ZG 1000 A9-A20 Concours 1994 to 2006
ZX 1000 B1/B2/B3 Ninja ZX10 1988 to 1990

Suzuki also used this caliper on the VX800, GS500 and the GSX1100G


Prototype steel brackets mounted on a 1978 GS1000:

Forks:
Suzuki GS550 (83-86) GS750SD GS850 all GS1000 all GS1100ET/EX/EZ/ED/ESD/GZ/GD/GLZ/GLD/LT/SD GS1150 all used 37mm forks. Caution: Some models use leading axle forks and can not be swapped without the triple.

GS550 (77-82) GS550MZ GT550 GS650 (except Katana) GS750B/C/EC/N/EN/ET/EX/EZ/LT/LX/TZ/TD all used 35mm forks. Caution: Some models use leading axle forks and can not be swapped without the triple.



DSCN2445.jpg

DSCN2447.jpg
 
Last edited:
Looks like it's gonna work! Are those 2 or 4 piston calipers?

Terry
 
Sweet! Are you going to lose the wire wheels Jeff or is the mag just for mock up?
 
Hoomgar said:
Sweet! Are you going to lose the wire wheels Jeff or is the mag just for mock up?
Click to expand...

I think I'm going to have to...Either the front rim is out of round, or the tire was molded incorrectly. The front jumps around a bit at low speed. I'm afraid better brakes will only compound the problem. :(
 
Last edited:
8trackmind said:
I think I'm going to have to...Either the front rim is out of round, or the tire was molded incorrectly. The front jumps around a bit at low speed. I'm afraid better brakes will only compound the problem. :(
Click to expand...

Do you know how to tune them? If so I can almost guarantee that is what it needs. The tire is new but that front rim was severely out of whack after I got the running flat last year. Also, I believe the front is the one that has a bad spoke nut? It still holds the spoke but is cracked. Please look at it closely if you plan to re tune it.

I redid it and it was true but my experience with these is that after one is out of whack as bad as this one was it will need to be re tuned a few times over time as you ride on it to walk it back in. For sure lose it if it doesn't feel safe. The mags look great and work well too but they add unsprung weight as they are heavier.
 
Hoomgar said:
Also, I believe the front is the one that has a bad spoke nut? It still holds the spoke but is cracked. Please look at it closely if you plan to re tune it.
Click to expand...

I know how to tune 'em but, to tell you the truth, I don't plan on messing with it. I'm all about low maintenance, thats why I ride a GS. :-D
 
Very interesting 8Track. Did you go with the single discs due to a larger diameter or is there something else that makes them work better than the twin discs? Keep the updates comming. Ray
 
Ghostgs1 said:
Very interesting 8Track. Did you go with the single discs due to a larger diameter or is there something else that makes them work better than the twin discs? Keep the updates comming. Ray
Click to expand...

Using the larger disks allows you to bolt the caliper to the upper mount, so only a lower bracket has to be fabricated.
The other benefit is a larger swept area. The downside is weight.:(
The Ninja calipers seem to be a bit lighter than the stock GS calipers, so it may even out...

Btw, The reason I don't have both calipers mocked up in the photo, is because the guy I got them from sent me two right's.
I got another pair from a 1994 on ebay today with new pads for...get this...$19.95. You guys need to start snatching these up!
3f_1.JPG
c2_1_b.JPG


I'm using steel spacers now but...Anybody want to make me some aluminium spacers?
 
Last edited:
Awesome post, Jeff. Most guys who've ridden these bikes and a newer bike will agree they need better brakes. That being said, this should be a popular thread!

To confirm what was required, you could not use the original rotors from a dual-disc setup because they were not a large enough diameter?

I guess my only beef is it was tough to find a drilled single rotor for the front on my old 550...finding two would be rough. Used brake rotors wear and warp too...and new ones are $200 from BikeBandit. :(

What did you end up using for the master cylinder? You're going to need to match the ratio for the new calipers!

~Adam
 
AOD said:
To confirm what was required, you could not use the original rotors from a dual-disc setup because they were not a large enough diameter?
Click to expand...

Correct. The smaller rotors could be made to work, but the caliper hanger would need more modification.
The great part about using these calipers is that the caliper hanger is steel, not aluminium. So you could weld it

AOD said:
I guess my only beef is it was tough to find a drilled single rotor for the front on my old 550...finding two would be rough. Used brake rotors wear and warp too...and new ones are $200 from BikeBandit. :(
Click to expand...

Most of the small bikes had the single rotor. Just have 'em drilled. I've seen ones off a GS450 go on ebay for $.99!

AOD said:
What did you end up using for the master cylinder? You're going to need to match the ratio for the new calipers!
~Adam
Click to expand...

Good question! :-D
Kawasaki is great about using one part forever. The master cylinder from any 600, 750 '88 to 97 Ninja, or Concours will work.
 
Kawasaki is great about using one part forever. The master cylinder from any 600, 750 '88 to 97 Ninja, or Concours will work.
Click to expand...

Ah, but that's where the fun stops! Kwackasaki uses a reverse threaded mirror, so you'll need an adapter to make the threads go back the other way...

~Adam
 
AOD said:
Ah, but that's where the fun stops! Kwackasaki uses a reverse threaded mirror, so you'll need an adapter to make the threads go back the other way...

~Adam
Click to expand...

Yamaha uses two LHT mirrors. All the normal bikes have one left and one right.
 
You must log in or register to reply here.

Similar threads

G
1981 GS1000G front brake upgrade project
Replies
13
Views
2K
GS1000G Shopper
G
8
Better Brakes for the GS:
Replies
3
Views
818
salty_monk
salty_monk
Back
Top