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Sticking front brakes

Started by Waiex191, October 18, 2023, 09:05:16 AM

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Waiex191

Jacked up the front wheel.  Verified that the brake frees as soon as the lever is released. Got my son to help me.

Next we compressed the forks, I think to the stop, and locked them in place with a cam strap.  No signs of locking up.

So far that puts me at a loss.  The aftermarket brake lever is nice and free.

My brake lines from RPM came today. Can anybody tell me what these things are for?

Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 

fj1289

If I remember correctly - they are used to clock the fittings.  The "stic goes through the banjo to lever it around while you hold the fitting in a vice using the "clamp".


Waiex191

Quote from: fj1289 on October 30, 2023, 09:31:36 PM
If I remember correctly - they are used to clock the fittings.  The "stic goes through the banjo to lever it around while you hold the fitting in a vice using the "clamp".

So, they do swivel.  I had tried by hand and failed, and thought I misunderstood.
Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 

Waiex191

Thanks, I ended up clocking one fitting a few degrees.  Also regarding your comment on aftermarket levers, I did find my lever was pushing in the master a little bit hands off. I filed down the stop that the green arrow is pointing toward.


Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 

RPM - Robert

That appears to be the stock lever for the 03-05 (06ish) FJR masters that are used with the blue spots. It should not have needed any material removed.

Waiex191

Quote from: RPM - Robert on November 01, 2023, 10:19:39 AM
That appears to be the stock lever for the 03-05 (06ish) FJR masters that are used with the blue spots. It should not have needed any material removed.
Here is the item on ebay I bought:
https://www.ebay.com/itm/323930918730

They identify it as aftermarket.  It did look a little different finish than the broken OEM one I took off.  Also the bushing looks to be aluminum rather than bronze.  So I think it is a close copy.
Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL
 

fj1289

Hope that clears up the problem for you!  In my case it just slowly built up more and more pressure and locked up about half way to work.  Don't remember how I figured what the problem was - think I finally realized that was the last thing I had messed with! 

RPM - Robert

Yup pretty close copy. I didn't look close enough in the original picture to see the bushing was not brass.

Pat Conlon

Old brake lines look fine on the outside but can shed little bits of rubber inside.
This stuff can clog the Masters relief port.

Good on ya for getting new Spiegler lines....
1) Free Owners Manual download: https://tinyurl.com/fmsz7hk9
2) Don't store your FJ with E10 fuel https://tinyurl.com/3cjrfct5
3) Replace your old stock rubber brake lines.
4) Important items for the '84-87 FJ's:
Safety wire: https://tinyurl.com/99zp8ufh
Fuel line: https://tinyurl.com/bdff9bf3

Waiex191

Quote from: RPM - Robert on November 01, 2023, 07:17:24 PM
Yup pretty close copy. I didn't look close enough in the original picture to see the bushing was not brass.
It was well-greased in that picture so would have been hard to pick out.
Bryan
1989 FJ1200
1981 Suzuki GN400
Poplar Grove, IL