Front Master Cyliner

[joker88]

I'm looking for some advice if anyone could help at all. i am a fairly aggressive rider and am finding that my front brake lever needs to be pulled to close to the bar for my liking. would someone be able to tell me if, A: it would be because master cylinder needs to be rebuilt or B: if it because of size of master cylinder, would an upgrade be a better idea. the caliper has just been rebuilt and fluid has been fully changed and system has been omprehensively bleed(mechanic used bleeding machine). also have just installed new slotted rotor and ebc hh pads so nothing down at the wheel is the problem. upon saying that i think the backing tabs on caliper have worn so inside pad only getting half contact on rotor but that easy to fix just replace caliper. with the upgrade master cylinder what models SPECIFICALLY will bolt on with minimal adjustments. i have heard of sv650's, gsx1100's and gsx600's. even heard of more modern gs ones being used. could someone please qualify which one exactly i should be looking for. thank you for any assistance anyone can offer   

[BaltimoreGS]

Before you replace the master cylinder have you swapped the rubber lines for braided steel lines?  If not, you are probably feeling the expansion of the rubber.  Also, do you have an adjustable brake lever and is it in the farthest open position? 

-Jessie

[joker88]

yes to the brake lever no to the steel lines their on the books. found some online for bout 30 a line

[GAS]

If everything else is fine (i.e. no air in the system) you'll probably need a rebuild kit for the master cylinder.

I'd bleed it a few times just to make sure that's the problem is not air.

Rebuilding it is extremely easy anyway..

[adidasguy]

Buy this new front caliper:
http://www.ebay.com/itm/09-Suzuki-GS500F-GS500-FRONT-RIGHT-BRAKE-CALIPER-/190537729135?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item2c5cef046f

I buy lots from Pinwall. They always describe the parts accurately and have good photos. Ignore the $14.95 price. They price a part at a fixed price. ANY front caliper will be that price. Look at the photos, the year and then buy. trust me on this: I've bought from them and replaced the calipers on my bikes with 2009's or 2008's. Even replaced the forks in Junior with 2009 ones I bought from Pinwall.

Buying a good 2009 with nearly new pads is soooooo much easier and cheaper than rebuilding old ones.

They have newer master cylinders, too:
http://www.ebay.com/sch/pinwall_cycle_parts/m.html?_nkw=gs500+brake&_sacat=0&_odkw=&_osacat=0&_trksid=p3911.c0.m270.l1313

[tricky]

I got HEL brake lines on mine, I recall the pricing was fair. They do make a difference.. my mechanic also hooked me up with a sturdy brand of brake fluid that doesn't fade and can take abuse. I'll ask him what it was exactly and get back to you

[joker88]

will a 2009 caliper bolt straight on. what about the 2009 master cylinder is that a better master cylinder then the stock on the 89.

[adidasguy]

caliper bolts right on. Been there - already did it. Direct replacement.

Advantage of a 2009 MS? It's newer. Not worn out. All the rubber and stuff is fresh and like new. I think they're a little bigger. I know the window is towards the rider rather than facing forward so the reservoir I think is a little higher & holds more.  I took off one of those old ones and put on the newer one.

I go with nearly new used OEM rotors. Cheaper than after market ones and probably much better.

If you pull in the brake lever and the front wheel doesn't lock up - you need new parts. Something is worn out. Is your rotor too thin?

[joker88]

well just priced new caliper and master cylinder from wreckers, they want $215 aud. for both which not bad. bit that has me annoyed is just spent dollars on rebuild of my caliper only to find it not straight. question for adidasguy, does the pads from the 89-94 caliper fit the 09 one just put in set of ebc hh pads and would like to keep using them.

[adidasguy]

What wreckers did you go to? That's highway robbery. 
I believe I suggested Pinwall. They are cheap and really excellent quality.
$14.95 for the calipers I pointed out.

Here's the whole thing from a 2006. Just needs a new lever:
http://www.ebay.com/itm/suzuki-gs500-gs-500-front-brakes-master-cylinder-caliper-engine-2006-/220889386773?pt=Motorcycles_Parts_Accessories&vxp=mtr&hash=item336e088f15
(I'd snatch it up if I didn't have so many on the shelf already).

It is important to remember that price means nothing to bike breakers. Some, like Pinwall, have a fixed price for a part whatever the year or condition. They deal in volume and can't evaluate each part.

Some price things ridiculously low just to get it out the door. I bought a 2006 wiring harness, CDI, coils, all relays and other stuff for $65! Shop and yea shall find!

I paid attention to my front brake today. Can't pull lever in any more than 3/4 the way - and that's hard to do. Pull in 1/2 and I stop - even down hill. You've got something wrong if you pull the lever all the way to the grips.

Pads changed with the change in calipers. Burning1 knows exactly the years, but I do know the old calipers with pistons of 2 different sizes - the pads are not compatible with the newer calipers. Buy those calipers from Pinwall and you have nearly new pads. No need to change them. I looked at their photos - perfect pads.

[joker88]

thanks for the link i asked him if he could hold them till Tuesday next week my time. my e-bay showing 22.50 which no biggy only few dollars when talking about a $200 saving. sorry to be pedantic but I'm a bit peculiar about making sure things are right before i part with money, are you absolutely sure i can bolt 06 caliper onto 89 forks and the disc will run true and the pads will mesh square on the disc. thanks for your advice it has been hugely helpful

[adidasguy]

Yes. Did that to Junior - my 1992.
While they made changes to the mfgr of the calipers, they did not change the mounts on the forks.

[joker88]

thanks for that hopefully he gets back to me soon and will hold them for a week. the only reason i think my brakes are pulling me up at all is the new disc and hh pads cause that lever comes frighteningly close the the grip.