Post by wayne on Apr 6, 2016 18:15:59 GMT -5
Your RE5 project will almost certainly require the rebuilding of the front brake callipers and master cylinder.
Kits are still available new from Suzuki and are interchangeable with the disc braked GT750 LMAB model waterbottles. There are also reproduction calliper kits available from Japan. Master cylinder reservoirs, caps and diaphragms are all still available from Suzuki but may not be identical to original parts.
Master Cylinder rebuild kit (piston and cup set)- 59600-45811 (current part number)
Calliper rebuild kit: 59100-18834
The new Master Cylinder kits are slightly different from the originals. The photo below shows the correct order of reassembly. Contributors to the forum's discussion on Master Cylinder rebuilds have noted that the flat silver washer should be left out due to differences in the size of the piston. For information, I have rebuilt them both with and without the silver washer (purely from not realising) and they seem to work equally as well.
As well as cleaning the master cylinder, the bore itself may need a light hone. If you cannot find a hone small enough, you can make one using a short piece of dowel. Slot the dowel lengthways to about half its diameter. Wrap wet and dry sandpaper of an appropriate grade (start with 800 and go either way according to results) as if you were winding on an old 35 mm film roll. Wrap enough wet and dry so that the fit inside the bore is such that it's snug but still loose enough to turn. Immerse the whole lot in a basin of water and use an electric drill (preferably battery operated) to spin the dowel to achieve a hone of the inner bore. I have used this method on two bores, one quite markedly pitted and both have lasted leak free for more than a decade. Severely degraded bores can be relined but you'll need to research this yourself.
If you are doing a complete refurbishment of master cylinder, hoses and callipers, you may consider changing to DOT 5 silicon. Silicon should not be mixed with other grades of Brake Fluid and that is why a change should only be done during a full refurbishment. Brake fluid is not as damaging to paint as it once was but using Silicon makes fluid changes a lot more relaxing.
There are numerous brake pad brands still available (same as LMAB waterbottles and later versions of the K) (Vesrah and EBC to name just a couple).
There are no real tricks with the Calliper kits, just make sure that the seal grooves inside the callipers are thoroughly cleaned. Brake fluid accumulates in them and dries out and requires some elbow work to get it out. Best to do a good job now than have to rebuild again a year or so due to leaking seals.
Contents of a genuine Suzuki calliper rebuild kit circa 2013:
Group discussion about brake callipers and commonality led to the following guide:
While there is commonality between RE5 and GT750 front brakes, it is limited to the GT750 LMAB models with most RE5’s common with only the MAB GT’s.
The RE5M and RE5 A use two different types of calliper. The very early M models used the GT750L style of calliper which had a stub on the end of the banjo fitting where it bolts to the calliper. This stub mates with a pin that protrudes from an enlarged boss on the calliper forward of where the banjo is bolted.
GT750 L calliper-
Early model RE5 M with the "L" style calliper-
GT750 M, A and B callipers-
The later RE5M and A callipers are common with the GT750 M, A and B models.
RE5 M and A calliper-
The K model GT750 had a calliper designed to take solid brake lines and is not readily compatible with the RE models-
HOSES: These are not the same as the GT750. Several hoses on the RE5 are longer. Correct hose lengths are no longer available from Suzuki.
If you are after a period look:
From board member GOANDY:
Cruzinimage is a company that manufactures brake hoses in the old style for the GT750. Below are comparative measures of original RE5 hoses and Cruzinimage GT750 hoses.
The measurements quoted are the length of exposed rubber between the metal end fittings, the second measurement for each hose is the Cruzinimage length:
Master cyl to splitter (top banjo): 360mm vs 295
Bottom splitter long hose: 275mm vs 234
Middle splitter long hose: 250mm vs 235
Both short caliper hoses are 150mm vs 135
Member HGH770N notes that the above picture shows early model RE5 short hoses (with the "pin" on the end of the banjo). These are the same as the L model waterbottle and possibly some late model K's.
Member NAIRB notes that the shorter Cruzinimage (lower) hoses fit but are tight with the front suspension fully unloaded.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
If you're not concerned with a "period" look braided lines are available and more recently, braided lines with a PVC coating in colours of your choice. Black gives a good compromise look and passes for period at a glance.
HEL in the UK manufacture this type of hose and include stainless steel banjos and copper crush washers in their kits. They have a kit listed for the GT750 but will alter lengths to your specs for the same price. There is an agent in Brisbane, Australia, and very likely more than one in the US.
To be continued................
Kits are still available new from Suzuki and are interchangeable with the disc braked GT750 LMAB model waterbottles. There are also reproduction calliper kits available from Japan. Master cylinder reservoirs, caps and diaphragms are all still available from Suzuki but may not be identical to original parts.
Master Cylinder rebuild kit (piston and cup set)- 59600-45811 (current part number)
Calliper rebuild kit: 59100-18834
The new Master Cylinder kits are slightly different from the originals. The photo below shows the correct order of reassembly. Contributors to the forum's discussion on Master Cylinder rebuilds have noted that the flat silver washer should be left out due to differences in the size of the piston. For information, I have rebuilt them both with and without the silver washer (purely from not realising) and they seem to work equally as well.
As well as cleaning the master cylinder, the bore itself may need a light hone. If you cannot find a hone small enough, you can make one using a short piece of dowel. Slot the dowel lengthways to about half its diameter. Wrap wet and dry sandpaper of an appropriate grade (start with 800 and go either way according to results) as if you were winding on an old 35 mm film roll. Wrap enough wet and dry so that the fit inside the bore is such that it's snug but still loose enough to turn. Immerse the whole lot in a basin of water and use an electric drill (preferably battery operated) to spin the dowel to achieve a hone of the inner bore. I have used this method on two bores, one quite markedly pitted and both have lasted leak free for more than a decade. Severely degraded bores can be relined but you'll need to research this yourself.
If you are doing a complete refurbishment of master cylinder, hoses and callipers, you may consider changing to DOT 5 silicon. Silicon should not be mixed with other grades of Brake Fluid and that is why a change should only be done during a full refurbishment. Brake fluid is not as damaging to paint as it once was but using Silicon makes fluid changes a lot more relaxing.
There are numerous brake pad brands still available (same as LMAB waterbottles and later versions of the K) (Vesrah and EBC to name just a couple).
There are no real tricks with the Calliper kits, just make sure that the seal grooves inside the callipers are thoroughly cleaned. Brake fluid accumulates in them and dries out and requires some elbow work to get it out. Best to do a good job now than have to rebuild again a year or so due to leaking seals.
Contents of a genuine Suzuki calliper rebuild kit circa 2013:
Group discussion about brake callipers and commonality led to the following guide:
While there is commonality between RE5 and GT750 front brakes, it is limited to the GT750 LMAB models with most RE5’s common with only the MAB GT’s.
The RE5M and RE5 A use two different types of calliper. The very early M models used the GT750L style of calliper which had a stub on the end of the banjo fitting where it bolts to the calliper. This stub mates with a pin that protrudes from an enlarged boss on the calliper forward of where the banjo is bolted.
GT750 L calliper-
Early model RE5 M with the "L" style calliper-
GT750 M, A and B callipers-
The later RE5M and A callipers are common with the GT750 M, A and B models.
RE5 M and A calliper-
The K model GT750 had a calliper designed to take solid brake lines and is not readily compatible with the RE models-
HOSES: These are not the same as the GT750. Several hoses on the RE5 are longer. Correct hose lengths are no longer available from Suzuki.
If you are after a period look:
From board member GOANDY:
Cruzinimage is a company that manufactures brake hoses in the old style for the GT750. Below are comparative measures of original RE5 hoses and Cruzinimage GT750 hoses.
The measurements quoted are the length of exposed rubber between the metal end fittings, the second measurement for each hose is the Cruzinimage length:
Master cyl to splitter (top banjo): 360mm vs 295
Bottom splitter long hose: 275mm vs 234
Middle splitter long hose: 250mm vs 235
Both short caliper hoses are 150mm vs 135
Member HGH770N notes that the above picture shows early model RE5 short hoses (with the "pin" on the end of the banjo). These are the same as the L model waterbottle and possibly some late model K's.
Member NAIRB notes that the shorter Cruzinimage (lower) hoses fit but are tight with the front suspension fully unloaded.
---------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
If you're not concerned with a "period" look braided lines are available and more recently, braided lines with a PVC coating in colours of your choice. Black gives a good compromise look and passes for period at a glance.
HEL in the UK manufacture this type of hose and include stainless steel banjos and copper crush washers in their kits. They have a kit listed for the GT750 but will alter lengths to your specs for the same price. There is an agent in Brisbane, Australia, and very likely more than one in the US.
To be continued................
