Need suggestion for replacement master cylinder

 

Turns out the front master cylinder for the Suzuki DL650 is on
indefinite back-order.

Anybody have a suggestion for an alternative that might actually be
available.  It's a 7/8 inch handlebar.

Alternatively anybody know of a good motorcycle junkyard in the
Hartford-Springfield area?

Or any other suggestion on how to fix this

Note that it appears to be cast aluminum--while welding is not right out
it's likely to cost me more than a new cylinder.

 

J. Clarke wrote:

There is no way in the world I would consider welding that.  Even assuming
it can be done, it's pointless since there are lots of similar bikes
serving as parts donors.  Your master cylinder was used before it broke...

There's plenty of bike junkyards that will ship anywhere, and of course ebay.
Many Jap bikes use very similar master cylinders, and as long as the piston
diameter is the same or close to the same as the original, you'll be OK.
Sometimes the lever perch has a locating nub that goes into a hole on the
bars, so you might have to grind that off, or drill a new hole.

While I was searching ebay I also found brand new radial master cylinders
that will fit the DL650, for about $100 including shipping, which is still
less than the OEM price.  Just another option to consider.

I don't know what year your DL650 is- but these models all use the same
master cylinder (Per Babbit's online parts lookup):

DL1000 (2002)
DL1000 (2003)
DL1000 (2004)
DL1000 (2005)
DL1000 (2006)
DL1000 (2007)
DL1000 (2008)
DL1000 (2009)
DL650 (2004)
DL650 (2005)
DL650 (2006)
SV1000 (2003)
SV1000 (2004)
SV1000 (2005)
SV1000S (2003)
SV1000S (2004)
SV1000S (2005)
SV1000 (2006)
SV1000 (2007)
SV1000S (2006)
SV1000S (2007)
SV650 (2003)
SV650 (2004)
SV650 (2005)
SV650 (2006)
SV650 (2007)
SV650A (2003)
SV650A (2004)
SV650A (2005)
SV650A (2006)
SV650A (2007)
SV650S (2003)
SV650S (2004)
SV650S (2005)
SV650S (2006)
SV650S (2007)
SV650SA (2003)
SV650SA (2004)
SV650SA (2005)
SV650SA (2006)
SV650SA (2007)
SV650 (2008)
SV650A (2008)
SV650S (2008)
SV650SA (2008)

 

On 5/17/2010 12:01 PM, Mark Olson wrote:

I've got inquiries in to some of the bike junkyards already, but,Geez,
why didn't I think to check ebay.  There's a bunch of them out there.
FWIW, the bike is a 2007 non-ABS.

Thanks for reminding me.  Problem solved (assuming the guy on ebay
doesn't rip me off).

Any thoughts on whether there's any point in going with a radial?

 

J. Clarke wrote:


There's really no good reason in my mind why it would matter on a DL650.
FWIW, the original 1st gen SV650, with its low-tech brakes, was on the
top 10 list of Motorcycle Consumer News best braking bikes ever, for
a number of years.  Whatever M/C and calipers the DL has are probably
pretty comparable.  I know I did an inadvertent rolling stoppie once on
my SV without much provocation when I grabbed a handful of brake due to
a brain dead cager cutting me off.

The one thing you can do easily to improve the brakes on almost any Jap
bike is to replace the stock rubber hoses with braided stainless ones.
It will make the lever feel firmer and give better feedback, regardless
of what type of M/C or calipers you have.

 


You might also ask around on DL650-specific forums, like this one:

http://www.stromtrooper.com/

Someone may have some insight into how to get the part you need quicker.

Datesfat

P.S.--I'm a little surprised to hear of the indefinite backorder.  I thought
that cycle manufacturers as a matter of policy made sure that the parts were
available for 15 years.