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Brakes upgrade

Ask questions and discuss technical items here. Tighten till it strips, then back out a half turn.

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BillWest
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Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 9:45 am

I'm in the process of upgrading the OEM Tokico brakes on my '02 ZZR1200.
I have always found braking on this bike to be underwhelming and less than satisfactory, even with braided lines, new pads, etc.

I intend to fit a set of NISSIN calipers, from a Concours (GTR1400).
To do this, I bought a set of adapters so that the 108mm C-C Nissin calipers can fit.
It effectively converts it to a radial type setup.

The adapters come from Taiwan.
The Nissins were on eBay.



I replaced the Tokico calipers on my ZX12R (when I still owned one) with Nissins: 1-finger braking, and a direct fit.


On my ZRX1200 (pic attached), I sourced a set of adapters from the same place as these a couple of years ago, eBay'ed a set of Nissin calipers, and did the conversion. Once again, 1-finger braking.
ZRXNissin.jpg
ZRXNissin.jpg (251.66 KiB) Viewed 653 times
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BillWest
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Re: Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 9:49 am

The adapters for the ZZR1200 arrived 2 weeks ago.
Brackets.JPG
Brackets.JPG (243.74 KiB) Viewed 651 times

The Nissin calipers arrived a few days ago. They are straight off a 2013 Concours, and according to the supplier, have had only 436 miles of use. They look spotless.

Image
Calipers.JPG
Calipers.JPG (221.97 KiB) Viewed 651 times

OEM Tokico calipers will be removed, adapters fitted, and Nissin calipers attached.
OEMBrakes.JPG
OEMBrakes.JPG (219.96 KiB) Viewed 651 times
My OEM disks originally had shudder problems when braking. I then replaced them with some China imports which were ok but harsh on my brakepads, always making a grinding noise when braking.
I replaced them with ZX12R disks a few years back. No shudder, no noise, no issues.

I will keep the same master cylinder, as I did with the ZRX.
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BillWest
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Re: Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 1:41 pm

Disconnect brake line.
LineOff.JPG
LineOff.JPG (244.02 KiB) Viewed 640 times
Tokico removed. Adapter attached, a bit of blue Loctite on the threads.
AdapterOn.JPG
AdapterOn.JPG (225.25 KiB) Viewed 640 times
Caliper is on. A bit more blue Loctite.
CaliperOn.JPG
CaliperOn.JPG (254.79 KiB) Viewed 640 times
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BillWest
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Re: Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 1:43 pm

Same on the other side.
OtherSide.JPG
OtherSide.JPG (232.67 KiB) Viewed 639 times
Compare.
Compare.JPG
Compare.JPG (227.34 KiB) Viewed 639 times
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Re: Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 1:45 pm

They sit a bit lower than the Tokicos, ie centre of gravity is slightly different.

Next:

Refill brake fluid and bleed the brakes.
Ride, bed the brake pads in.

:D
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Re: Brakes upgrade

Post by BillWest » Sun Apr 15, 2018 3:56 pm

Filled.
Bled.
Ridden.
Bedded.
Tested.

Faark, what a difference. Night and Day. Chalk and Cheese. The duck's nuts. The ant's pants.

1 finger stopping with these calipers.

:D
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Buzz
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Re: Brakes upgrade

Post by Buzz » Tue Apr 17, 2018 12:12 am

Glad you know what you're doing Bill.
Buzz.
Many thanks for putting the Pot Luck Photos on the website.
Buzz.

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Boxer
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Re: Brakes upgrade

Post by Boxer » Fri Apr 20, 2018 11:02 am

.
.
Hmm . . . very interesting.

I too bought some of these calipers, they were attached to my 1400.

Anyway, I prefer twin leading shoe breaks.

My latest acquisition has them:

180413 bmw r25 1.jpeg
BMW R25/3
180413 bmw r25 1.jpeg (131.37 KiB) Viewed 583 times
180413 bmw r25 3.jpeg
BMW R25/3
180413 bmw r25 3.jpeg (167.42 KiB) Viewed 583 times
180413 bmw r25 4.jpeg
BMW R25/3
180413 bmw r25 4.jpeg (146.89 KiB) Viewed 583 times



Boxer
.
.
non tantum ut olei ad pulmentum

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BillWest
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Re: Brakes upgrade

Post by BillWest » Tue Jul 03, 2018 4:54 pm

I had two separate issues to deal with with this upgrade.

1. There was extra drag that I noticed when spinning the front wheel.
That was solved by adding spacers behind the discs. These spacers were originally only for the C3 (later) model ZZR1200s. Mine is a C1.
However, I think that aftermarket discs are made with the newer models in mind.
I put a set of those spacers on, and no more drag. Wheel spins quite freely.
The thickness of each spacer was just enough to move the disc ever so slightly away from the wheel..
.
Spacer.jpg
Spacer.jpg (57.39 KiB) Viewed 243 times
.
2. I discovered that one of my (non OEM) discs was warped after all. I didn't notice it with the original Tokico calipers, but certainly did with the Nissins. I think that tolerances with the Nissins are tighter.
So, a new set of discs installed.
.
NewDiscs.JPG
NewDiscs.JPG (248.09 KiB) Viewed 243 times
.
I did a test ride today, and I was more that happy with the result. After bedding in the brake pads with the new discs, the brakes performed as I expected (just like on my ZX12R I had, and my ZRX1200). Definitely a huge improvement over OEM, and 1-finger stopping.

The ride also gave me a chance to check the performance after installing the stick coils. Starts well, idles nicely, and doesn't hesitate anywhere.
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