GSF1200 Sunstar Premium Disk & RMZ Pad Service KIT Main Harness Replacement (OEM Parts) Headlight Relay USB ETC Installation and More

dsc_1944
Sunstar Premium Disk & RMZ Pad Service KIT was also requested.

Depending on the caliper, T=5.5mm can be used, so please definitely consider it.

The weather has been uncertain, so I’ve been doing some cleaning and a bit of work.

p1620802
This is what we have now. Since it’s a crimped type, if you use it hard in sports riding and such, there will be more distortion. I recommend something with holes open a bit more than slits.

dsc_1946
The new one has this hatch and makes a really pleasant sound. It’s like a “shoo-shoo” biting sound.

p1620804
Manual spec is 23N. I always wonder how much I should trust a torque wrench. And I suspect hardly anyone actually maintains their torque wrench.

For example: following the manual with a new bolt and the mating surface as-is, tighten with a torque wrench, and then it loosens and falls off—whose responsibility is that? It’s a troubling question.

Hand feel is important too.

p1620805
Suddenly… that’s so Japanese.

p1620806
New pads lately don’t get chamfered much.

p1620808
Chamfering the top and bottom surfaces reduces the contact width = the disk wears in that shape = the I-shape becomes tighter than normal use. I think chamfering is effective for disks that are already worn.

Chamfering is effective for worn disks, I believe.

p1620807
The inlet and outlet direction is the same. On the leading side, there’s a possibility that debris can more easily enter the pad. The outlet side sometimes gets “rough,” so maybe that’s okay?

There’s some subjectivity here, so feel free to do as you like.

p1620801
Well, it’s only 0.5mm, but it does get a bit heavier. The piston retracts that much more, so the touch feels firmer. Of course, it will deliver plenty of performance for hard riding.

p1620809
Even though it’s titanium, it’s still a bit short, so I’ll replace it with a Yamaha one.

dsc_1954
It goes “shoop!” right away.

p1620800
They wanted a mud guard on the back of the carburettor. I have one from my GSF, so I’ll give it to them.

dsc_1947
It’s fixed by hooking with a pin and tab on the top surface. It needs to be easy to attach and detach.

p1620813
Layout is pretty much done. The harness is straightforward too.

p1620814
The headlight area is simple as well.

p1620810
We might go single-seat eventually, so the layout isn’t too elaborate.

p1620812
The left side can’t be helped. Rather than forcefully clamping it down with cable ties, if you just keep the routing as parallel as possible and avoid tangling, it looks clean.

dsc_1951
The ETC mechanism works well too, so you can store dried fish or similar items.

p1620815
I won’t label what each thing is for. It’s plastic, lightweight, and has plenty of capacity.

p1620816
It feels like you could fit a “goo!” in there.

p1620817
They used to have a tray on the upper cowl, but it’s no longer needed, so I’ll remove it.

p1620818
It’s better not to tighten plastic with metal bolts. I’m sure everyone feels a bit uneasy when tightening them. And once the plastic dents or shrinks, it loosens right up and disappears.

p1620821
Unusually, the mating part is M6, so it becomes a rather large push rivet.

p1620819
This type tends to stick out quite a bit, so let’s cut it off.

p1620820
There’s no problem with opening and closing.

Pretty much complete.

 

 

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