Topic: Who's done the old dual disk setup

[Tintop]

Once youv'e sourced your parts the next issue will be caliper / disk alignment, and then the speedo drive.

There are (by my count) 3 methods for aligning the disk & caliper.  Shimming the caliper mount & possibly the disk / filing or machining the the lower mounting boss / machining the pivot pin.  The 1st 2 are detailed in various posts (use the search function), the 3rd is the method I used.  It is described on pg. 8 of my build. http://forums.sohc4.net/index.php?topic=70130.175.

There is also a thread in Tips & Tricks regarding modifying the speedo drive plate to work with dual disks.

[xfactor]

Once youv'e sourced your parts the next issue will be caliper / disk alignment, and then the speedo drive.

There are (by my count) 3 methods for aligning the disk & caliper.  Shimming the caliper mount & possibly the disk / filing or machining the the lower mounting boss / machining the pivot pin.  The 1st 2 are detailed in various posts (use the search function), the 3rd is the method I used.  It is described on pg. 8 of my build. http://forums.sohc4.net/index.php?topic=70130.175.

There is also a thread in Tips & Tricks regarding modifying the speedo drive plate to work with dual disks.

Mucho thanks, that seems like the easier way, but seeing as I am not a machinist and only have access to hand tools, looks like I will be using a file!

[Tintop]

Once youv'e sourced your parts the next issue will be caliper / disk alignment, and then the speedo drive.

There are (by my count) 3 methods for aligning the disk & caliper.  Shimming the caliper mount & possibly the disk / filing or machining the the lower mounting boss / machining the pivot pin.  The 1st 2 are detailed in various posts (use the search function), the 3rd is the method I used.  It is described on pg. 8 of my build. http://forums.sohc4.net/index.php?topic=70130.175.

There is also a thread in Tips & Tricks regarding modifying the speedo drive plate to work with dual disks.

Mucho thanks, that seems like the easier way, but seeing as I am not a machinist and only have access to hand tools, looks like I will be using a file!

The guy in town did mine for $15, just told him how much to remove.

[JS550]

Or go the GL front end route. Bolts right on, little bigger forks. I put one on my 750, drilled gl disks w/ a nissin 5/8 m/c, works excellent. No squeally cb stops!

[seaweb11]

Once youv'e sourced your parts the next issue will be caliper / disk alignment, and then the speedo drive.

There are (by my count) 3 methods for aligning the disk & caliper.  Shimming the caliper mount & possibly the disk / filing or machining the the lower mounting boss / machining the pivot pin.  The 1st 2 are detailed in various posts (use the search function), the 3rd is the method I used.  It is described on pg. 8 of my build. http://forums.sohc4.net/index.php?topic=70130.175.

There is also a thread in Tips & Tricks regarding modifying the speedo drive plate to work with dual disks.

Mucho thanks, that seems like the easier way, but seeing as I am not a machinist and only have access to hand tools, looks like I will be using a file!

I used a big rasp/file on my Tracy forks and just kept doing a little bit and trying it until I had it just right. 4 tries maybe? You don't want to remove to much.

[xfactor]

So my next question is one in which I have been having problems. What did you do for a brake light switch?

[MCRider]

So my next question is one in which I have been having problems. What did you do for a brake light switch?

I'm not sure what you have now, mine was in a junction block bolted to the lower tree. So you can get a longer bolt to stack the banjos on. I'd guess places like Z1 has them.

I thinned the banjos with a file until I could comfortably stack them on the stock bolt, keeping the stock brake light switch. Took a while but worked fine.

[xfactor]

So my next question is one in which I have been having problems. What did you do for a brake light switch?

I'm not sure what you have now, mine was in a junction block bolted to the lower tree. So you can get a longer bolt to stack the banjos on. I'd guess places like Z1 has them.

I thinned the banjos with a file until I could comfortably stack them on the stock bolt, keeping the stock brake light switch. Took a while but worked fine.

Did you get a longer double banjo bolt then file down the banjo fittings?

[MCRider]

So my next question is one in which I have been having problems. What did you do for a brake light switch?

I'm not sure what you have now, mine was in a junction block bolted to the lower tree. So you can get a longer bolt to stack the banjos on. I'd guess places like Z1 has them.

I thinned the banjos with a file until I could comfortably stack them on the stock bolt, keeping the stock brake light switch. Took a while but worked fine.

Did you get a longer double banjo bolt then file down the banjo fittings?

Nope, used the stock bolt.

[Tintop]

So my next question is one in which I have been having problems. What did you do for a brake light switch?

I'm not sure what you have now, mine was in a junction block bolted to the lower tree. So you can get a longer bolt to stack the banjos on. I'd guess places like Z1 has them.

I thinned the banjos with a file until I could comfortably stack them on the stock bolt, keeping the stock brake light switch. Took a while but worked fine.

Did you get a longer double banjo bolt then file down the banjo fittings?

Nope, used the stock bolt.

Filing will certainly work, along as you are very careful to keep the faces parallel.  Otherwise you will have leaks.  Easiest and safest is a double banjo, and reuse the existing brake switch.

If your changing MC's, most newer ones have a switch built into them.  That opens the option of running lines from your calipers direct to the MC, and using a double banjo there.

[Mavryk03]

Okay, I swear I've searched this a billion times but I just now found this - http://www.sohc4.net/index.php?q=content/dual-disk-conversion-cb750
Is this using another of the same caliper that I already have or do I need to source a right side caliper?

ok so from this form the pg found about how to do a duel disk set up, is that pretty much how you do and all the parts you need, im getting all the stuff from tintop to do the swap, so dont know if there is anything else to know do i need to get a GL m/c, i have a cb550F? thanks

[fatmatt650]

do i need to get a GL m/c,

Consensus seems to be that your stock m/c will work, especially if you upgrade to steel braided hoses but that a dedicated dual disc m/c with its larger brake fluid volume is better.

Has anyone had any issues w/ hardware not matching up, i.e stock hoses not attaching to aftermarket or other brand m/c?

[Mavryk03]

yeah i figured that if i do the duel set up more fluid means bigger m/c so who has a GL m/c for sale in good working order  i will look in the bike and parts forum 

[cwchan]

has anyone had any fitment issues with the speedometer gearbox assembly with the boltheads after adding the 2nd disc?

[xfactor]

has anyone had any fitment issues with the speedometer gearbox assembly with the boltheads after adding the 2nd disc?

Yes you need to get a different spedo drive disk. There is an aluminum machined one in the for sale section for 45 or you can attempt to fit one off another 550 or 750 or something. Check the FAQ section.


http://sohc4.net/index.php?q=content/dual-disk-conversion-cb500550

[cwchan]

has anyone had any fitment issues with the speedometer gearbox assembly with the boltheads after adding the 2nd disc?

Yes you need to get a different spedo drive disk. There is an aluminum machined one in the for sale section for 45 or you can attempt to fit one off another 550 or 750 or something. Check the FAQ section.


http://sohc4.net/index.php?q=content/dual-disk-conversion-cb500550

see picture attached.  Notice where the speedo gearbox could hit the bolt when the wheel is turning? The pic isn't a stock disc so its kinda a bad example.  i'll take some pics when i get home.

[MCRider]

Yes that can be a problem. On my CB750K2 I thinned the nuts with a grinder.

I've since bot thin nuts. You may be able to send the bolts thru the other way and the heads of the bolts may be thinner.

[Ricky_Racer]

OEM GL1000 rotor bolts have thinner heads.    RR

[MCRider]

OEM GL1000 rotor bolts have thinner heads.    RR

Yeah that was a fix, but I think they are discontinued.

[Ricky_Racer]

Yep.  Nuthin's easy.    RR

[Steve F]

This link below will show a few things that I ran into while doing the conversion.  First the speedo drive was modified, and the right side rotor was milled to accept the drive disc and a shim was required on the right side fork to get the caliper to align with the rotor.  I bought some long 5/16 bolts in stainless steel from McMaster-Carr and faced the bolt heads a bit in the lathe to get them to clear the speedo drive.

And finally, the finished conversion.

Steve F

http://forums.sohc4.net/index.php?topic=53532.msg574499#msg574499

[xfactor]

This link below will show a few things that I ran into while doing the conversion.  First the speedo drive was modified, and the right side rotor was milled to accept the drive disc and a shim was required on the right side fork to get the caliper to align with the rotor.  I bought some long 5/16 bolts in stainless steel from McMaster-Carr and faced the bolt heads a bit in the lathe to get them to clear the speedo drive.

And finally, the finished conversion.

Steve F

http://forums.sohc4.net/index.php?topic=53532.msg574499#msg574499

Thanks Steve!


Some great info and honestly dosent seem like it will end up being that hard, but I will need to employ the help of some local honda guys, seeing as I dont have a lift and some other various things.



When fitting the new rotor, do you need to remove the center hub? or can you just remove the front wheel and use the longer bolts?

[xfactor]

OEM GL1000 rotor bolts have thinner heads.    RR

What year rotor bolts should I be looking for? I have found some off a 81-82 but nothing earlier then that. You think these will work? By the way I found it all on ebay.

[cwchan]

This link below will show a few things that I ran into while doing the conversion.  First the speedo drive was modified, and the right side rotor was milled to accept the drive disc and a shim was required on the right side fork to get the caliper to align with the rotor.  I bought some long 5/16 bolts in stainless steel from McMaster-Carr and faced the bolt heads a bit in the lathe to get them to clear the speedo drive.

And finally, the finished conversion.

Steve F

http://forums.sohc4.net/index.php?topic=53532.msg574499#msg574499

i wish i saw this post last week i already ground my speedo drive plate down...

[Tintop]

OEM GL1000 rotor bolts have thinner heads.    RR

What year rotor bolts should I be looking for? I have found some off a 81-82 but nothing earlier then that. You think these will work? By the way I found it all on ebay.

I purchased SS bolts 10mm longer than the stock 550 ones.  Put the head on the speedo side, and they cleared the speedo (just!).  Lots of room for the nuts on the other side.