How To1980 Suzuki Gs750 Front Brake Line Replacement

How to Replace Your 1980 Suzuki GS750 Front Brake Line: A Step-by-Step Guide

Replacing your 1980 Suzuki GS750's front brake line might seem daunting, but with the right tools and a methodical approach, it's a manageable task. This guide provides a step-by-step walkthrough, ensuring you complete the job safely and effectively. Remember, safety is paramount when working on your motorcycle's braking system.

Tools You'll Need

Before you begin, gather the necessary tools. Having everything ready will streamline the process and prevent interruptions:

• New front brake line: Ensure it's the correct length and specification for your 1980 Suzuki GS750. Double-check compatibility before purchasing.
• Wrench set: You'll need various sizes to handle the brake line fittings.
• Adjustable wrench: For added flexibility in tightening and loosening.
• Brake line flaring tool: Essential for creating the proper flare on the new brake line ends.
• Tube cutter: For cleanly cutting the old brake line.
• Socket set: Possibly needed depending on your caliper mounting bolts.
• Clean rags: To keep everything clean and prevent contamination.
• Brake fluid: You'll likely need some to bleed the brakes after the replacement.
• Safety glasses: Protect your eyes from brake fluid splashes and potential debris.
• Gloves: To keep your hands clean and protect them from brake fluid.

Step-by-Step Replacement Process

This guide assumes a basic understanding of motorcycle maintenance. If you're unsure about any step, consult a qualified mechanic.

1. Preparation is Key

• Safety First: Always wear safety glasses and gloves. Park your motorcycle on a stable surface and engage the kickstand.
• Drain the Brake Fluid: Before disconnecting any lines, carefully drain the brake fluid from the master cylinder reservoir. This prevents spills and air entering the system.
• Locate the Brake Lines: Identify the front brake lines connecting to your calipers and master cylinder.

2. Removing the Old Brake Line

• Disconnect the Lines: Use your wrenches to carefully disconnect the old brake lines from the calipers and the master cylinder. Be prepared for some brake fluid spillage.
• Remove the Old Line: Gently detach the old brake line from any mounting brackets or clips.

3. Installing the New Brake Line

• Prepare the New Line: Use the tube cutter to carefully cut the new brake line to the correct length, ensuring enough slack for movement.
• Flare the New Line: Use the flaring tool to create the proper flares on both ends of the new brake line. This is critical for a proper seal.
• Connect the New Line: Carefully connect the new brake line to the calipers and the master cylinder, ensuring the connections are tight and secure.

4. Bleeding the Brakes

• Reconnect the Reservoir: After securely installing the new brake line, refill the master cylinder reservoir with fresh brake fluid.
• Bleed the System: Use a brake bleeder to carefully bleed the air out of the brake lines. This is essential to restore proper braking function. Refer to your motorcycle's service manual for detailed bleeding instructions.

5. Final Checks

• Test the Brakes: After bleeding the brakes, carefully test them several times, ensuring firm and consistent braking action.
• Inspect for Leaks: Thoroughly inspect all connections for any leaks.
• Reassemble: Securely reattach any removed components.

Troubleshooting

• Leaking Brake Line: If you notice any leaks, carefully re-check the connections and flares. If the problem persists, you might need to replace the brake line.
• Spongy Brakes: This usually indicates air in the brake lines. Re-bleed the system thoroughly.
• No Brakes: If you experience no brake action, immediately inspect the entire system for any issues and consult a mechanic.

Remember to consult your 1980 Suzuki GS750 service manual for specific details and diagrams. This guide provides a general overview; specifics might vary slightly depending on your motorcycle's exact configuration. Always prioritize safety and consult a professional if you are uncomfortable with any step of this process.