ZZR brake upgrade

[wr6133]

The stock Tokico 4 pots fitted too ZZR400/600's are dire, even well looked after they are spongey and vague. So I replaced them.

Callipers are from an early ‘blade (92-97) cost me the princely sum of £13 posted. These are definitely not just a case of bolting on with some added spacers a fair bit of filing is required.

I got lucky on the callipers. They had been listed on fleabay with a silly title, bad photo and potato grade description. This meant I was the only bidder. When they arrived they had been packed with broken up polystyrene which had dissolved with the old brake fluid they were dripping, so they required a good strip and clean.

Here they are after a clean.
https://i1249.photobucket.com/albums/hh504/wr6133/n1_zpsif7pfwis.jpg

Next was to decide my mounting method. The old tokicos used an m10 bolt, these use an m8. I don’t have the tools to tap these out to m10. I didn’t want to use shouldered bolts as I was not confident in their strength. So I used top hat spacers. Bought off ebay, bit of an extravagance but these ones also deal with the spacing so no messing about with washers.

https://i1249.photobucket.com/albums/hh504/wr6133/n2_zpsxwqqduem.jpg

The shape of the calliper means to get it to mount flush you need to file the leg a little. This throws ali filings everywhere, because of this ideally do it with the leg off the bike. However as I was working between rain showers I didn’t fancy pulling the front end off so did it in place.

(Rag is to try to limit the spread of filings)
https://i1249.photobucket.com/albums/hh504/wr6133/n3_zpsdypnlvjh.jpg

Not much needs removing. Fancy tools are not essential here I did it with a small £2.50 file.
https://i1249.photobucket.com/albums/hh504/wr6133/n4_zpsalza3smo.jpg

Next the callipers themselves need to be attacked with the file. If you don’t then the edge of the disk rubs slightly.
Again can be done with a small file.
https://i1249.photobucket.com/albums/hh504/wr6133/n5_zpsxopkjznt.jpg

The arrows show (roughly) the 2 points that will touch the disk if not filed. I’d estimate I took off 2-2.5mm.
https://i1249.photobucket.com/albums/hh504/wr6133/n6.1_zpsfsjc5mz5.jpg

Once it was done I fitted them, hooked them up and bled them. Well actually I snapped a banjo bolt, cursed a lot, fitted a new one and then bled them.
https://i1249.photobucket.com/albums/hh504/wr6133/n7_zps0tfb85xh.jpg
https://i1249.photobucket.com/albums/hh504/wr6133/n8_zpsnzb7snju.jpg

The pin and spring thingy just about clear the disk.
https://i1249.photobucket.com/albums/hh504/wr6133/n9_zpssbxlbdb8.jpg

The mudguard is absent from the above pictures because that too needs attacking with a hacksaw and file. The bleed nipple on these Nissins is higher up than the Tokico’s (or some newer Nissins). This means a small amount needs removing from the mudguard.

I plan on replacing these plastics soon, so didn’t bother doing an elegant job.

Pre hacksaw attack
https://i1249.photobucket.com/albums/hh504/wr6133/n10_zps7w4hwzp2.jpg

Post attack
https://i1249.photobucket.com/albums/hh504/wr6133/n11_zps3ikdqsnc.jpg

Quick blast from rattlecans
https://i1249.photobucket.com/albums/hh504/wr6133/n12.1_zps1d6yw6tx.jpg
https://i1249.photobucket.com/albums/hh504/wr6133/n13_zpstvpixzjt.jpg

[chrisdubya]

Its good that the bolt holes line up and no brackets need to be made!

I'm looking at a similar thing for my '99 hornet 600, I've done the usual braided lines, new pads and fluid but they still aren't great