Kawasaki Twinpot Brake Modification - who wants parts?

[Old Colt]

Hi Dan,
One item I do not understand with your setup here.
Why do you need spacers behind the rotors?
Why not use your caliper adapters as spacers and move the calipers inwards as needed?

[salty_monk]

Mainly because there is not enough space between the wheel spokes & the fork legs to get a decent thickness of spacer between the 2....

I wouldn't want the caliper bottom bolt only attached to 1/8" material, would you?

Dan

[Old Colt]

I wouldn't want the caliper bottom bolt only attached to 1/8" material, would you?

If it is the proper material, sure. Especially since that is all the caliper bracket is. If working with aluminum use 7075 alloy.

[salty_monk]

The caliper bracket on mine is at least 4 or 5mm & it's not Aluminium it's steel & appears to be a hardened variety... The part the bolts go through including thread is approx 8mm.

What would concern me most about using that setup is that if the caliper got knocked it would have enough leverage to bend the bracket, it would also be very tight between caliper & the wheel.

Each to their own I guess, this way is working out fine & is almost identical in position, rotor thickness etc to how it is as stock on the Kawasaki.

Dan

[Old Colt]

I thought your disc spacer was thicker than 1/8.

I expect the Bandit calipers I used may be a bit smaller than the Kawi units. Mine has plenty of room to the spokes and the Suzuki bracket is is only about 4mm thick but is extruded where the fasteners are.

[salty_monk]

I would think so given that they newer. I would prefer them on the inside if it was feasible because I think it would probably give a cleaner look.

Don in Australia has managed to work something with my brackets on the inside but he doesn't have such a "near stock" positioning that I have although it's not too far off.

Dan

[Suzuki_Don]

I would think so given that they newer. I would prefer them on the inside if it was feasible because I think it would probably give a cleaner look.

Don in Australia has managed to work something with my brackets on the inside but he doesn't have such a "near stock" positioning that I have although it's not too far off.

Dan

Dan I am going with another idea now. I am not going to use your brackets. I have developed a new bracket that is almost not visible to the eye that fits on the inside of the fork lugs. I have made them from steel plate and am using a different threaded hole on the Kawa caliper bracket. There are four holes on the Kawa bracket and there are a few options available to the would be modifier. I am now using the two threaded holes that the standard Kawa uses. When I get a chance I will put up some pics of the new brackets and the overall setup on the 550.

Picture of Kawa setup below.

[salty_monk]

Be interested in seeing the pics Don

[Suzuki_Don]

Be interested in seeing the pics Don

Dan see pics below of brackets. they weigh 1 oz more than the aluminium brackets.

[Suzuki_Don]

These are the calipers fitted with the steel plates. The plates will be painted black to match the calipers and will not be very noticable when finished. I now have 8mm clearance on both sides of the wheel between the disc and the caliper bracket as discussed earlier, also in UJM site.

[salty_monk]

Looks great Don! I guess those are 6mm steel?

I'll take a look to see if it's an option on the 1000 but if there is room behind the caliper to move them over that much then it will definitely need to be closer to the rotor than 8mm to get a decent size bracket in there.

Cheers,

Dan

[hp1000s]

Hello Suzuki-Don,
What brand/model front rotors are those?
Thanks,
Hugh

[Suzuki_Don]

Looks great Don! I guess those are 6mm steel?

I'll take a look to see if it's an option on the 1000 but if there is room behind the caliper to move them over that much then it will definitely need to be closer to the rotor than 8mm to get a decent size bracket in there.

Cheers,

Dan

Dan the brackets are 5mm steel plate. Really sturdy and gives me the correct clearance (8mm) which we spoke about as the clearance on the stock Kawa setup between the disc and caliper bracket.

[Suzuki_Don]

Hello Suzuki-Don,
What brand/model front rotors are those?
Thanks,
Hugh

Hi Hugh. The rotors are off an early 90s Honda CBR900RR model. Overall diameter of 296mm. The later 90s model CBR900RR were 310mm so don't use these ones. All of them have the correct bolt hole arrangement to bolt the rotor up to the front hub. Although the 6mm holes need to be drilled out to 8mm to fit the GS front hubs. I believe the same 296mm rotor was also on the CBR600F3 models as well. These are the rotors that Dan has used on his brake upgrade project. The only difference I can see is the holes drilled in the disc surface are a different pattern. The offset could be a bit different as well, I am not sure. Worth checking though.

[hp1000s]

Thanks much!!!