Kawasaki ER5 ER500 front brake upgrade [guide]

[john24ssj]

Hello guys,

Just as promised I will try to write a short simple guide of how I upgraded my front brake on the ER-5.

I did not quite like the front brake performance on my ER5 so I decided to upgrade it, I found of that C series ER-5 models had a newer different calliper which I was going to buy and install BUT they were just too hard to come across.

Then I found out that ER-6 had the same looking calliper as the newer ER-5 C series, and there were plenty of them on ebay to buy so I did.

So on ebay I bought: KAWASAKI ER6 N 2008 LEFT HAND FRONT BRAKE CALIPER:
https://i.imgur.com/4iXyVE4.jpg


Then I removed the old calliper and put on the new one to check if it fits properly:
https://i.imgur.com/o7FdTOd.jpg
https://i.imgur.com/aexNKVn.jpg
https://i.imgur.com/S4W5m7M.jpg


And it seemed to be the perfect fit : ) Next I bled the old system to remove all the brake fluid:
https://i.imgur.com/4Jjf2bq.jpg


Removed the brake line from master cylinder:
https://i.imgur.com/AGJ1HJs.jpg


Removed everything to clean the disk from all the crap:
https://i.imgur.com/lAx5jWO.jpg


Next the new ER6 calliper went back on and was fully tightened:
https://i.imgur.com/0i44C1L.jpg


From there I installed a new Wezmoto braided brake line:
https://i.imgur.com/jSCtNyo.jpg


Installed other end to the master cylinder. Before tightening the brake line checked for clearance:
https://i.imgur.com/Rrl5xQX.jpg
https://i.imgur.com/R164t2W.jpg


And got everything nice and tight:
https://i.imgur.com/uGbAaII.jpg

ALL done (then obviously bled the system).
Now I only went fro a short 5 minute ride but the brake seems much better, level is still spongy as I think there still is some air in the system but even with that front brake feels more gripy and responsive.

After I completely remove all the air and go a longer ride I will post impressions.

Hope this helps anyone who wants to change the front brake
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Bikes: Honda CBR600Fi, Kawasaki ER5

[john24ssj]

OK a small update, after I got all the air out of the system the braking is much better. Not saying it's superb but much better than the old original calliper.
Brake seems to work earlier and has a better bite.

Hope this helps anyone who would like to change their ER5 callipers
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Bikes: Honda CBR600Fi, Kawasaki ER5

[wots]

Shame I didn't see this, as I have a spare in my garage doing nothing, since I did this last year, if you think your brakes are good now, imagine if you had this.
https://i1312.photobucket.com/albums/t525/wotsthestory/Bike/DBB91C23-E9D6-432C-AC35-0B4C36CDF08E_zps57ujmg1e.jpg~original
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[wots]

Check the disc size, as I've got some spare discs and they'd look great on there and probably improve it yet further.
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[john24ssj]

Well that's interesting. So you got an adapter to fit brembo brake calliper on?

Well look at the website it says that ER-5 fits:
OD:280mm
ID:130mm


So do these discs have different metal compositions from stock EOM ones?
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Bikes: Honda CBR600Fi, Kawasaki ER5

[wots]

I bought the calipers and the brackets together. There was a place that did them I think. I was lucky and picked them up cheap off eBay.

The discs are likely to have much less fade than those you have.
____________________
Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125

[john24ssj]

Thanks wots I'll look into the discs but they seems quite pricey.
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Bikes: Honda CBR600Fi, Kawasaki ER5

[Matt B]

What is the actual difference in spec between the old ER5 caliper and the new ER6 one you fitted? Different piston sizes?

Just wonder whether you would have got the same improvement from a decent set of pads, new fluid and a braided line on the old calipers.
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stinkwheel: He had an animated .gif of a cat performing fellatio. It's not socially acceptable. It can have real life adverse effects on other people.

[john24ssj]

[wots]

Those callipers are Ducati items, I think off a Ducati Monster before they went to radials. They are immense, but the forks dive heavily.
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Currently: Yamaha DT 125 LC2,Repsol Fireblade, and Bumblebee MSX 125