A disc brake modification using Suzuki and Yamaha parts - full instructions
I had some interest in the brake modification I did to my Mk.lll 850, so here's a quick overview of what I did. The conversion worked out quite well; taking the following steps:-
(1) Mount the disc rotor to Norton hub with adaptor plate
(2) Mount the caliper to the fork leg with adaptor plate
(3) Assemble caliper and rotor and shim to centralise
(4) Mount master cylinder; fabricate SS lines
I wish I could say that I had CAD drawings of the adaptors that I could email to you, but that is not the case. I designed them in the best traditions of cafe racers everywhere; by hand drafting the key dimensions on paper, and then developing the finished shapes on cardboard templates.
(1) The 1989 Suzuki GSXR 1100 disk has a centre hole that is a little larger i.d. than the spigot on the Norton hub, and the bolt holes are on a larger circle than the Norton disc, so the first thing you need to do is to machine an adaptor plate that sandwiches the disk rotor to the hub. This plate is made from ½" 6061 T6 alloy, machined so that the spigot is the thickness of the disk rotor hub, with the remainder left for the clamping surface for the plate. The spigot in the plate is raised in its centre in order to centralise the disk on the hub ,and locate it. The o.d. of the whole thing is the diameter of the depressed center of the rotor. Once the sandwich plate is machined; mark out, drill, and then countersink holes in the plate to match up with the original holes in the Norton hub. Lastly, drill holes in the hub of the Suzuki brake disk rotor to line up with the Norton hub. Assemble the sandwich plate and disc to the Norton hub with 5/16" UNF flat head Allen screws, torqueing them evenly.
(2) The 1986 GSXR 4-piston caliper is light, works well, and is easy to find. A similar version was also used on the Gamma 550. There is lots of choice in pads; I used ones with Kevlar linings. I mounted my GSXR 1100 caliper on an alloy plate made from 3/8" 6061 T6 sheet. The plate bolts to the outside surface on both the caliper's mounting lugs, and the two lugs on the Norton fork lugs. I considered making the plate extend downward to pick up one of the smaller lugs. Originally, the shape of the plate is designed so that it hugs the outline of the caliper, and overlaps the lugs on the forks to the greatest extent possible.
(3) Assemble the disk onto the hub if you haven't already, and install the completed wheel into the forks. If you're using the late GSXR disk, you will likely find that the grommets will lightly foul the fork slider. Fix this by installing a small distance piece on the axle between the fork leg and the bearing in the hub. Bolt the caliper plate solidly to the fork leg, and align the center line of the caliper on the rotor. Make up distance pieces to suit the required amount to space the caliper on the plate. When you're finished deburring smoothing and polishing, ensure everything is tight, and be sure to use at least Grade 5 bolts and nuts.
(4) I used a Yamaha XV550 master cylinder with a 13mm bore. It mounted very nicely inboard of the standard Norton switch gear, and looks 'right'. You may choose to retain the Lockheed master, but lever travel may be limited, and the hydraulic brake light switch is marginal at best. What ever you do, spend the money on braided stainless/teflon lines.
The final thing I did on my bike was to fabricate a right side mirror mount, since using the Yamaha master cylinder means the loss of the stock mounting boss. I machined a suitable 'L' shaped mirror mounting from a block of 1" x 1" x 2" 6061 T6 alloy, which bolts to the upper two screw holes for the original master cylinder mounting in the twist grip, and juts forward to pick up the mirror stalk, which threads (10mm x 1.0) into the alloy.
Greg Kricorissian (
grkricor@ccs.carleton.ca) on NOC-L 16th. Sep 1997