SuzukiSavage.com - Gentlemen Behold: Dual Disc Front End for LS650

philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #60 - 09/03/19 at 14:49:49

This is the new setup. The risers are the same height and pullback as the OEM risers. But the handlebars are much wider with a little more pullback than the original dragbars.
While riding my Ducati I realized that one big reason I can keep control of the bike during emergency stops is because the handlebars are wide like a dirtbikes. All that leverage is to your benefit with stupidly strong brakes.

But these wide bars require all new hoses, cables and wiring. Yay! Shocked

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #61 - 09/03/19 at 14:50:30 A closer shot.
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #62 - 09/06/19 at 16:00:11

Zero time all week for tinkering but I just did some test fits and measurements. With longer grips the bar controls come inboard enough that the wires and throttle cable reach fine at both steering stops. Clutch cable not quite. Magic number for brake line is 2.5 inches. Need to decide on 2-line or over the fender. I don't run a fender so that's easy.
The Superbrace does not fit the Kwak forks. Close but no cigar so I'm thinking of heading to the machine shop again to see what they say about that.

So I'm having the tire mounted to the Kwak wheel this weekend and ordering custom brake lines. And a longer clutch cable.
Additionally I'm gonna bolt everything up for real and take a stab at getting the calipers put back together and mounted.

So much for the picture. Apparently an error has occurred....

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #63 - 09/07/19 at 10:54:31 Dropped the wheels and tires at the shop for mounting and balancing. Also left the calipers for him to remove the pistons from. I don't have an air compressor and no tools I could pull them out with without damaging them. Need to order the rebuild kits for them still. I need to write a checklist....
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Fast 650

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #64 - 09/07/19 at 11:40:35

There is a way to get the pistons out without an air compressor. Swap the bleeder screw for a grease fitting and thread a bolt in where the brake line goes. Connect the grease gun and start pumping, it will force the pistons out.
Just make sure that you remove all traces of the grease before you reassemble it afterwards so that the grease doesn't attack the seals.

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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #65 - 09/07/19 at 13:32:27

That's pretty inventive. In my case I wouldn't even be concerned for the seals since I'm replacing them anyway.
I was thinking of trying to use my pressure washer but it prsented some safety concerns for me.

Anyways while I'm waiting on the shop I have the time to wire wheel the caliper brackets and paint them. Even though I cleaned everything thoroughly these look crappy from discoloration of whatever surface treatment they originally had.

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28786 L.A. California Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #66 - 09/07/19 at 14:33:31 Why not just use the master to pop them out?
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #67 - 09/07/19 at 18:36:41

The original brake and cylinder was pulled off the bike intact and set aside as a backup. If need be I can slap it back on and be up and running again in minutes.
That's just how I roll. Always have a rollback before proceeding.
Always plan ahead. Always plan for the worst.
I haven't done anything irreversible. Every nut and bolt accounted for.
Each original part and assembly ready for use. And nothing wasted.

Old habits from working on Navy jet fighters when I was in the service. It's also why I ask lots of dumb questions. The only truly dumb question is the one you didn't ask. Cheesy

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #68 - 09/08/19 at 11:13:29 Ahhh so much better now....
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #69 - 09/08/19 at 16:42:56

Ok I need help!
I'm looking for a master cylinder with 5/8" bore for 1" bars.
More specifically I'm trying to find which bikes with 1" bars have 5/8" bore MCs so I can get a cheap OEM takeoff and not spend an arm and a leg for some fancy gold plated, diamond crusted, gaudy thing for the discriminating Harley connoisseur.

Any ideas?

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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SpamyToo Full Member Offline Posts: 233	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #70 - 09/08/19 at 17:10:06 I imagine something for the Kawi Vulcan, Yam Vstar, or Suz Boulevard would work. black https://www.ebay.com/itm/1-Front-Brake-Master-Cylinder-Clutch-Yamaha-XVS650-V... chrome https://www.ebay.com/itm/1-Brake-Master-Cylinder-Clutch-Yamaha-XVS650-Vstar-R...
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philthymike Serious Thumper Offline Wallowing in my own crapulence Posts: 1413 Philadelphia Area Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #71 - 09/08/19 at 18:26:51 Cool! Thanks. I also discovered that the MC from a Suzuki Boulevard VL1500 C90 also fits the bill.
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philthymike

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Re: Gentlemen Behold: Dual Disc Front End for LS65
Reply #72 - 09/09/19 at 16:08:25

This is more to help me keep track than anything.
Wheels are done, picking them up tomorrow.
Master cylinder ordered and shipped, coming Friday.
Rebuild kit for calipers ordered and shipped, here Friday.

Tried measurements for custom hoses but pointless until new MC arrives.
Need to remember to ask shop guy about hoses because he might get them cheaper.

Need to email machine shop about Superbrace mod.

Once wheels are back need to assemble back brake and pulley hub bearing.
That reminds me, order cush drive rubbers...

And 16 other things leak through the sieve known as my brain....

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07 S40 (Thumpy): 666cc big bore, stage 2 webcam, dyna muffler, 412 shocks, Barnett clutch, Kawasaki ZL900 FE

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Dave YaBB Moderator ModSquad Offline SuzukiSavage.com Rocks! Posts: 17832 Camp Springs, Kentucky Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #73 - 09/09/19 at 17:49:32 Look at Venhill USA for brake hoses. You can order the color, length, and fittings you want.
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verslagen1 YaBB Moderator ModSquad Offline Where there's a will, I want to be in it. Posts: 28786 L.A. California Gender:	Re: Gentlemen Behold: Dual Disc Front End for LS65 Reply #74 - 09/09/19 at 21:48:38 philthymike wrote on 09/09/19 at 16:08:25: That reminds me, order cush drive rubbers... got a bunch of them, ryca take offs.
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