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H1 - h2 - kh500 dual disc conversion
here are some pictures of dual disc conversions for h1, h2, & kh500 models.

This is a factory kit installed on a 72 h2
The kit included a genuine opposite caliper. 
Due to the added caliper, the master cylinder was upgraded to a 5/8. Notice the 5/8 stamp on top.
The junction block also had to be changed. This dual outlet unit replaced the single one.

since the factory kits are no longer available & genuine parts are next to impossible to find, i came up with the following methods using parts from other models that were more easily obtainable.
 
 

caliper ID


KH-500

H1/H2
This is a stock caliper for the 1976 KH-500
This is a stock caliper for the 1972-75 H1/H2

Caliper conversion


KH-500

H1/H2
This picture shows a KH500 conversion. I used a bracket from a 1978 KZ 650 (which is an opposite to the KH500) & attached it to a spare KH500 caliper. It will then bolt on the right side. Since the bleeder & line are in the center, it is no problem to swap the caliper to the other side. The bracket is the only difference between the left & right side. The KH-500 & KZ's have the same bolt pattern. S3 calipers will also work on this setup.
This picture shows a 72 - 75 H1/H2 conversion. I used  Z1 calipers because the bolt pattern is the same & the bleeder & line are in the center. This makes it easy to use the caliper on either side. The H1 & H2 calipers have the bleeder & line on opposite ends, making the swap to the other side more difficult. The bracket however has to be modified for use on the right side as right side brackets are not available from another model.

master cylinder
I upgraded the master cylinder to a 5/8 unit from a mid 80's Suzuki GS. The stock lever had to be modified to fit the Suzi master. The banjo bolt also has a different thread.  If you can find a KZ dual brake master it is a bolt on swap. 
This is a also a mid 80's 5/8 Suzuki master. Any 5/8 unit will work however. I used the suzi masters because I was able to get them at a reasonable price. Again, I modified the stock brake lever to fit. This keeps a symetrical appearence.

junction block
This is a junction block from a 1977 KZ 650 with dual disc brakes. The only difference between this one & the genuine part is that the input line & brake light switch angle back slightly instead of pointing to the sides. This block is needed to convert H1b, KH500, & H2 models.
The H1d, H1e, & H1f (1973 - 1975) models have the junction built in. The line on the right is the stock brake line. The port for the second line is on the left, it is usually plugged with an allen head bolt. All you have to do is remove the bolt & install the second line. 

rotor id


KH-500

H1/H2
The 76 KH-500 & KZ models use a 4 bolt rotor.
The 1972-75 H1/H2 models use a 6 bolt rotor.

 
 


don't let this happen to you, upgrade those brakes today!
 

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