Kawasaki Twinpot Brake Modification - who wants parts?

[salty_monk]

It will work for one side but I'm pretty sure you'd have to either switch out to the dual caliper fork leg on that side or it would require you to "tweak" the mounting holes or even an entirely different bracket....

If someone can measure up a 550 fork leg for me (mainly distance from centre of the axle to centre of the mounting holes) I may be able to work out the difference.....

If it needs a completely different bracket I *may* be able to get some made at the same time.

It *should* work on the 1100/1150 as their disk is the same size & the caliper appears to be the same one as on my 80GS100G. Again, give me the Axle to mounting hole distance.

If I get them & it doesn't work out for people then I will refund minus postage on return. (to minimise your risk).

Thinking about it... I will try to measure up what I have here that I know works... & then perhaps people can feed back the info to me so we can see what we can figure out.

Dan

 

[willie]

NICE job on a well designed and executed product! The info re: calipers and discs is excellent and helpful as well. If they'll work on my GK, please count me in for a set.
Thanks,
Willie

 

[Mark M]

It *should* work on the 1100/1150 as their disk is the same size & the caliper appears to be the same one as on my 80GS100G. Again, give me the Axle to mounting hole distance.

Bike is an 82 1100E, all dimensions were taken in a couple of minutes in a dark corner of my garage. So take them as good approximations instead of absolutes...:-D

From center of axle to center of lower mounting hole is about 76mm, about 65mm if you measure along the centerline of the fork slider.

The caliper mounting bolts are about 73mm CtoC.

Stock rotor is approximately 275mm OD.

Am I in or not?\\/


Mark

 

[salty_monk]

It sounds like it! I will try to double check later today.

Dan

 

[Mark M]

It sounds like it! I will try to double check later today.

Dan

I managed to get out in the garage in daylight and re-measured my dimensions.

Axle to lower caliper mounting bolt - 75mm CtoC
Axle to lower caliper bolt, along fork slider axis - 65mm
Mounting bolts - 73mm CtoC

These are pretty accurate and should be useful for your confirmation.

Mark

 

[salty_monk]

Sounds the same to me taking into account I just did this roughly with a tape... That's 72, 68 & 140. The distance from centre of the bolt to edge of the fork leg is about 12mm

Dan

 

[Mark M]

Sounds the same to me taking into account I just did this roughly with a tape... That's 72, 68 & 140. The distance from centre of the bolt to edge of the fork leg is about 12mm

Dan

That definitely sounds the same. Suzuki is not likely to have two different fork sliders that differ by 1-2mm.

So I'm in for a set, too.:-D

Mark

 

[salty_monk]

Added a poll to help me keep count.

Talking with my colleague I think we might do some kind of brush or polish finish & I also hope to supply complete with the correct size bolts & washers etc.
The bolts cost me at least a buck each incl washers, 2 nuts etc & I could only find 50mm.

I added a Poll to try to help keep track of numbers.

Dan

 

[briyenkieth]

would these fit my little 400? if so where do sign up?mine only has a single disk and i would like to stop when i want. any improvement would be awesome.

 

[salty_monk]

Measure your disk & fork leg & have a look at the measurements I posted above.... I believe the smaller models used the 276mm disk the same as the duals disk bikes so the likely answer is yes.

Dan

 

[SqDancerLynn1]

I need a set too !! I to already have my ZX6 calipers

 

[TheCafeKid]

Ok im a lil slow on the uptake here. I will need rotors from a single rotor GS correct? And they will bolt up to my 1100G? If so, put me down for a set. And i will likely need a set later on as well, but i need to find forks for the cafe that will accept dual calipers.

 

[briyenkieth]

thanks monk! i printed out the page and will measure up tonight. if it measures out how do i get a set of your adapters?

 

[Suzuki_Don]

What is the solution for the bottom fork leg on the other side for the early GS bikes that only had one disc and have a fork leg with no mounting lugs. Mine is a GS550B, 1977 model. I think it has 35mm staunchions. Would 650 bottom legs work. What do people think is the best solution.

 

[8trackmind]

What is the solution for the bottom fork leg on the other side for the early GS bikes that only had one disc and have a fork leg with no mounting lugs. Mine is a GS550B, 1977 model. I think it has 35mm staunchions. Would 650 bottom legs work. What do people think is the best solution.

The 650 forks will work just fine on the 550 but...It would be better if you had the triple tree as well. Yours has ball bearings in the steering head, so you may be stuck with using it. It can be done with the stocker though. Here's how I did it. LINK
Just fitting the smaller dual disks is more than enough. I have the Kawasaki calipers and larger rotors on my 1000, but it would be overkill on my 550.

 

[TheCafeKid]

The 650 forks will work just fine on the 550 but...It would be better if you had the triple tree as well. Yours has ball bearings in the steering head, so you may be stuck with using it. It can be done with the stocker though. Here's how I did it. LINK
Just fitting the smaller dual disks is more than enough. I have the Kawasaki calipers and larger rotors on my 1000, but it would be overkill on my 550.

You can swap to the tappered bearings on the 77s, it requires either a more modern fork and tree (mainly for the stem) or for you to machine your stem. Frankly, finding and swapping the forks is an easier solution, as the bearing kits machining diagram isnt very clear on what it is you're machining. I have found on my 77 750, that the 78 forks will work, as the stem is already machined. You may find the same with the 550s later years, or with a different model fork.

 

[salty_monk]

Josh,

Larger rotors from a 550, these brackets (& I now hope to supply the bolts too) plus the ZX calipers.

I did mine for around $50 incl shipping buying from EBAY plus the bolts & brackets.

I hope to be bringing enough of them back with me in around 10 days. Keep you all posted.

Dan

P.s. Jeff - haven't forgotten you, just haven't got my act together (Too busy riding.... Nessism helped my Sync the skunk on Sat am, it's great!

 

[8trackmind]

P.s. Jeff - haven't forgotten you, just haven't got my act together (Too busy riding.... Nessism helped my Sync the skunk on Sat am, it's great!

No worries. I'm just glad to know their coming. :-D
Thanks again.

 

[Suzuki_Don]

You can swap to the tappered bearings on the 77s, it requires either a more modern fork and tree (mainly for the stem) or for you to machine your stem. Frankly, finding and swapping the forks is an easier solution, as the bearing kits machining diagram isnt very clear on what it is you're machining. I have found on my 77 750, that the 78 forks will work, as the stem is already machined. You may find the same with the 550s later years, or with a different model fork.

Thanks CAFE. I have a 650 triple tree. I will have to see if it will fit my GS550B frame. If so it will give me tapered bearings instead of balls and some extra width between the fork legs to fit bigger calipers in.

 

[salty_monk]

Jeff,

A set of the proto brackets went off to you this morning.... let us have some pics etc when you get them mounted.

I'm just about to get on a plane but I'm 99% sure I should be bringing some sets back with me in a week.

Dan