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From: J. Clarke on 17 May 2010 11:22
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
<http://www.flickr.com/photos/39383723(a)N00/sets/72157624079436816/>?

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.



From: Mark Olson on 17 May 2010 12:01
J. Clarke wrote:
> 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
> <http://www.flickr.com/photos/39383723(a)N00/sets/72157624079436816/>?
>
> 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.

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)

From: J. Clarke on 17 May 2010 14:55
On 5/17/2010 12:01 PM, Mark Olson wrote:
> J. Clarke wrote:
>> 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
>> <http://www.flickr.com/photos/39383723(a)N00/sets/72157624079436816/>?
>>
>> 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.
>
> 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)

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?


From: Datesfat Chicks on 17 May 2010 15:16
"J. Clarke" <jclarke.usenet(a)cox.net> wrote in message
news:hsrnel02bc8(a)news7.newsguy.com...
> 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
> <http://www.flickr.com/photos/39383723(a)N00/sets/72157624079436816/>?
>
> 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.

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.

From: The Older Gentleman on 17 May 2010 16:04
Datesfat Chicks <datesfat.chicks(a)gmail.com> wrote:

> I thought
> that cycle manufacturers as a matter of policy made sure that the parts were
> available for 15 years.

Nope.

--
BMW K1100LT Ducati 750SS Honda CB400F Triumph Street Triple
Suzuki TS250ER GN250 Damn, back to six bikes!
Try Googling before asking a damn silly question.
chateau dot murray at idnet dot com
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