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GS550E Brake Swap tutorial with Photos

  • Thread starter Thread starter 8trackmind
  • Start date Start date
Nerobro said:
This is why I went with the 650 fork. Now there's two 1980 gs550e's with dual front disks.

I used the original 550 master cylinder too. (smaller piston.. more pressure)
Click to expand...

Post some photos. I'd like to see it.
 
*grins* I'm afraid I'll get smacked by frank for using images *grins*

I"ll get some shots of my fork tonight.
 
Thanks.
Maybe this will help the next poor sap that attempts it.
 
Nerobro said:
*grins* I'm afraid I'll get smacked by frank for using images *grins*

I"ll get some shots of my fork tonight.
Click to expand...
Anyone else done this swap?
If so, let's see 'em.
DCP03527.jpg
 
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Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray
 
Ghostgs1 said:
Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray
Click to expand...
Thanks!
The biggest problem I ran into with the 4 piston calipers was: I'm fighting a narrower triple tree just to get a regular caliper in there and they are too wide. (contact the wheel) They will fit over the disk as is but...if they had new pads...I don't know.
I'll make you a fantastic deal on 'em if you want to try you're hand at it. I'd love to see somone get some use out of them. PM Me.
DCP03444.jpg

DCP03445.jpg

DCP03424.jpg
 
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Good Topic here 8track. I am currently in the process of performing the same swap on my 650L. I used the same forks you did (650E), so I changed the geometry slightly. I will have to get some pics taken. I have been cleaning and polishing along the way. I have the rotors mounted up, and the forks ready to go on the bike. BTW, I am using the master cylinder and calipers from another doner 650E. Didn't really think about using new stuff.
 
Ghostgs1 said:
Hi Jeff, This is a very interesting project you are working. Looks like the dual disc setup is working out well, as is the master cylinder. My question is, could the 4 pots work if you fab an alluminum bracket to adapt them to the fork bosses? Looks like it could be done, then the next question is, would they engage the disc sufficiently to take advantage of their greater clamping pressure? Sure is getting me thinking about looking into that swap. Keep the good work going there, very nice. Ray
Click to expand...


Here's a bit of inspiration for you:

DSC03271.JPG


I doubt the GS550 brakes are as reprehensible as those on the XJ turbo. These are R1 calipers attached with an adapter plate. These and some braided lines have transformed this particular bike (not mine) into a one finger tire howler. Rotors are also from an R1, which bolted up perfectly with no mods. Sorry about the pic size, not my site. I replaced my master cylinder with one from Parts N More designed for a dual disc XS1100 arrangement ($76 US). It has a larger 16.5mm piston than the original 13mm piston in the Turbo's master cylinder. Along with some Russell lines, these have transformed the brakes on my bike.
 
So yall wanted pictures right?

dd1.jpg

Here you can see my only "real" mod. There's 1/8" spacers in there.
dd2.jpg

dd3.jpg

dd4.jpg
 
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Nerobro said:
So yall wanted pictures right?
Click to expand...

Thanks. :-D I'm glad you woke this up. Those front brakes have saved my @ss more than once.
The problem is, I got used to them. Enter the GS1000 I bought from Hoomgar. Great bike, but the stock brakes are downright scary compared to My 550. Soooo.

I've worked up a new mod to mount a pair of early model dual piston Kawasaki Ninja calipers to a stock GS1000 front end.
(or any GS, really)
It will also use two of the larger single disk rotors, instead of the smaller dual disk rotors. :twisted:
I've mocked it up in the garage, and so far it looks really good.
I'll start a new thread on it after I get pictures.
Maybe there will be some interest in that one. :lol: Stay tuned.
http://www.thegsresources.com/_forum/showthread.php?t=98098
 
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At the risk of being accused of being "obsessed" with unsprung weight again, I have to ask why you would use those big heavy rotors?
 
The tradeoffs one is willing to make to be faster in int he straights. All I want is enough brake to lockup that front tire. I have it now. Brake fade is scary.
 
humhead said:
At the risk of being accused of being "obsessed" with unsprung weight again, I have to ask why you would use those big heavy rotors?
Click to expand...


Cuz your more likely to die for lack of stop rather then go.

JMO.


N_L
 
humhead said:
At the risk of being accused of being "obsessed" with unsprung weight again, I have to ask why you would use those big heavy rotors?
Click to expand...

The rotors will me modified. My plan is to at least have them drilled. I know it won't save much weight though.
Those Ninja calipers are a little lighter than the GS units as well.

However, the mighty GS1000 is on a diet even as we speak.
I've removed the centerstand, case guards, and put a RC 4 into 1 one on it.
The RC muffler is at least a foot shorter than the Kerker that was on it.
I'm also installing an aluminum 82 GS1100 swing arm this fall.

As heavy as I am, it'll kinda be like throwing a deck chair off the Titanic...It won't matter much. :lol:
 
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8track: Glad to hear you'll be drilling the rotors. Unsprung weight is an important factor in Ride quality & handling.
Ninja Lancer: You're just as likely to get in trouble if your bike doesn't respond quickly to rider input or changing road conditions.
 
humhead said:
8track: Glad to hear you'll be drilling the rotors. Unsprung weight is an important factor in Ride quality & handling.
Click to expand...

I agree.
I'm sticking with the spoked rims for that very reason. I know they're a liabilty, but they are a good deal lighter. Not sure how stable they are above 100 MPH, but I don't spend much time at that speed anyway. :)

Using a GSXR front end would solve all the problems, but it sure would kill the retro look of the old GS. Looks great on the 82 up GS's though.
 
humhead said:
Ninja Lancer: You're just as likely to get in trouble if your bike doesn't respond quickly to rider input or changing road conditions.
Click to expand...


Thanks for the reply. I thought you were talking about weight simply in terms of acceleration. As far as making a bike more nimble I agree. My primary ride is 343 lbs. But I'm not sure how an extra pound or two that far down the forks would hurt much? Some other iron parts have already been removed from the beast....... (Like the centerstand)
 
8trackmind said:
I agree.
I'm sticking with the spoked rims for that very reason. I know they're a liabilty, but they are a good deal lighter. Not sure how stable they are above 100 MPH, but I don't spend much time at that speed anyway. :)

Using a GSXR front end would solve all the problems, but it sure would kill the retro look of the old GS. Looks great on the 82 up GS's though.
Click to expand...

Correct thinking. And just so you know, those rims are good and very stable for speeds up to and beyond what the 1000 can do. Keep them true. I had tuned them just before you got them. Both were severely warped so it may be advisable to look them over again in a few hundred miles. Someone had chewed up a few of the spoke keeps so watch those when you get to them. You'll see them. They are still serviceable but you want to be gentle with them when tuning.

Sounds like some great mods coming up.
 
Ninja_Lancer said:
Thanks for the reply. I thought you were talking about weight simply in terms of acceleration. As far as making a bike more nimble I agree. My primary ride is 343 lbs. But I'm not sure how an extra pound or two that far down the forks would hurt much? Some other iron parts have already been removed from the beast....... (Like the centerstand)
Click to expand...
Unsprung is the worst place for it. I think that is what Terry was trying to tell you. A pound or two on the frame is not near as much of a deal as it is on the unsprung parts of the bike. I can tell you that on a heavy bike like the 1000 your don't want you wheels sliding, chattering or doing any other funky stuff when at speed.
 
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