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Kawasaki Front Caliper swap on a 2006 ZX10R
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Kawasaki Front Caliper swap on a 2006 ZX10R - August 16, 2009, 12:33 PM

Ok -

I bought my 06 10R about a year and a half ago and never really pushed it on the streets. For that, I entrusted my 636 at the track. Well, I went for a ride with OrangeShirtDude and a couple other guys on the board. It was a long ride and I didnt really know the route that well. So, I used the brakes a little more than I used to. Well, a little bit into the ride, the brakes go got EXTREMELY MUSHY. I LOST ALL CONFIDENCE in these pieces of crap.There a WHOLE thread and about how CRAPPY they are - http://www.zx-10r.net/forum/showthre...ghlight=brakes but I didnt pay much attention to it since I didnt really have a problem. Orangeshirtdude has a ZX10R and he idd the caliper swap. He swore by it. I took a look at his setup and I was convinced. I went to ZX10r.net and read the ENTIRE LONG ASS THREAD. People were trying different pads, master cylinders, lines, etc to no avail. Finally, a caliper swap did the trick. So - thats what I did. From what I remember, I believe 06 and newer CBR600rr or 1000rr calipers will work. People also were swapping out the calipers with ZX12 calipers. The one issue with that is that the ZX12 calipers are much more expensive than the Hondas. I believe I found the calipers for $30.00 a pair on E-Bay. Can go wrong with that! Honda's have a 5mm spacer between the caliper mount and the caliper. Thank you Ronayers! I believe they were 5.00 a spacer. The one thing different is that Honda's have a tab that goes into the calipers and mount. I just took my Demel while enjoying a NICE COLD BEER and cut off one tab off the spacer (since the other side is going into caliper). A little black spray paint and voila!

Now for the good stuff. I removed the stock calipers. Remember that you have to remove the brake line so have something ready to catch the brake fluid. That stuff eats paint. I installed a new set of pads (Carbon Lorraine's SBK5 I think the model number is). I finger tightened the caliper bolts at first because it seems that with the spacer, the caliper might not align correctly and cause a little wobble in the brakes. So, finger tighten the bolt, hit the brakes a couple times so it seats, and tighten. YAY!!

I hate the stock caliper bolts that come on the bike. SO, I replaced it with something else. I used Honda caliper bolts instead of the stock ones (Honda Part #95801-10060-00) is a 10x60mm so I can use a socket to make it easier to take the bolts off. I know this is a must of you change tires often (track people). SO - Im done. I still might replace the master cylinder but not sure yet. Well see how the new setup works. Ill probably bleed the system again after the ride to make sure all the air is out.

Nothing is better than pictures!!


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August 16, 2009, 12:38 PM

also - THANKS ORANGESHIRTDUDE for the advice and SHOOOM for finding me the deal on the Calipers!!!!


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August 16, 2009, 12:41 PM

I got electric...good brakes...Next Speedohealer, a map for the rapidbike and MotoGP shift!


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August 16, 2009, 04:07 PM

Nice!


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August 16, 2009, 04:27 PM

nice. i've been debating this for my 07. i've done some pretty good breaking, and so far, i haven't really noticed any issues. but seems maybe I don't know any better, haha.

Thanks for the part numbers and stuff, I'm probably gonna look into this for winter...
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August 16, 2009, 04:50 PM

Been there, done that with my '06 ZX-10! I was lucky enough to get the ZX-14 calipers with virtually no miles for very cheap about a year and a half ago. Thanks Vondari for the install! Here's a posting I did at ZX-10r.net:

http://www.zx-10r.net/forum/showthread.php?t=49847

(posting No. 17):

There are a couple of different goals when it comes to changing parts of your braking system. Some people are after more stopping power, including less fade when using the brakes hard (i.e., during spirited riding or on the track). Others are seeking to eliminate the spongy feeling of the Zx-10 brakes, which means you will be able to get enough stopping power without as much brake lever travel. For street riding, I felt I had enough stopping power with the original braking system, but I could not stand the spongy feel/travel of that system. So, my initial goal was to eliminate that travel. After that, I would deal with the fading problem for spirited rides (the brakes were fine for ordinary riding).

So, with that in mind, here is my experience:

1. I bled and bled and bled the lines. No difference.

2. I then changed to Galfer ss lines. No noticeable difference.

3. I then changed the pads to HH pads. No noticeable difference (in brake lever travel).

4. I changed the OEM calipers to Nissin calipers, got new Galfer HH pads. Huge difference!

So, in my experience, you should change the calipers first to eliminate the sponginess/travel issue. As for fading problems, they were eliminated by the new HH pads.

***

On a side note, there is still another problem with the front-end, which indirectly is affected by the front brakes and forks, as I and many others have described here: http://www.zx-10r.net/forum/showthread.php?t=43140.


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August 16, 2009, 05:34 PM

Kenneth, any time someone says that the gen1 and gen2 10r brake problems are due to anything but the calipers, I tell your story and how scientific you were about finding the problem.


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August 16, 2009, 05:43 PM

is this shimmy part of the reason why my bar wobbles during certain speeds? Noticed it when i take my hands off the bars, sometimes its worse than others.
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August 16, 2009, 08:55 PM

That could be a number of things..Tires could be off balance or the rotor is warped (bent if anything hit it)...bent rim....



But first off - do you have a real dampener on that thing? If you dont, I STRONGLY suggest you get one! The stock one is a PIECE OF GARBAGE and doesnt work for shit! That will probably get rid of your head shake.


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? - August 16, 2009, 10:15 PM

If you have the stock dampner on send it to this guy! Dan Kyle or www.Kyleusa.com He will rebuild it for you i heard it makes a world of difference! It's all about the needle inside the unit, has hole drilled through it!
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August 16, 2009, 10:34 PM

Well..I finally got to ride..

Pretty damn good if I do say so myself! Feels ROCK SOLID. This bitch stops on a dime. It was pretty dark and the roads I was on arent too well lit. But I pushed it a little and no fade. I promised a friend of mine that I would take her for a ride this week so that will be a true test!


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August 16, 2009, 11:29 PM

Quote:
Originally Posted by OrangeShirtDude View Post
Kenneth, any time someone says that the gen1 and gen2 10r brake problems are due to anything but the calipers, I tell your story and how scientific you were about finding the problem.
Hey Jon!! I hope you are still happy with your bike! It is a beaty! Wish I could be up there riding with ya--Florida just does not have the roads. But, it does have the weather, beaches, palm trees and a great job!!


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August 17, 2009, 07:17 AM

Glad you're enjoying Florida, Kenneth. Yeah, no roads but lots of other nice things.

I'm really enjoying the 10r. Just recently passed 36K miles and have no plans of replacing it at all. Just got my KTM on the street so I can relieve the commute burden from the 10 and save it for the weekends.

What I notice about the honda system is that there is no fade, but the bite is not unusually great. Once the brakes are on, it takes quite a bit of input to increase the braking. I mean I still only have to brake with one or two fingers, but they do not seem very linear in response. A freshly bled Kawi OEM system was more linear. However, the fade was too problematic. I think with the Honda calipers, a different MC might give a more linear response curve.


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December 2, 2009, 01:39 PM

Im about to do a fork leg swap....

On my 08 race I took my 25mm ohlins forks off my 06... basicaly took the whole 06 front end and put it on my 08.

So i been racing with my 08 with 06 calipers and forks, brembo 19x20 MC. hardest feeling brakes you will ever feel...

I had to down size my rotors and used all 300mm vs 310mm that came on the 08s.

Now
I want to keep my 06 forks, but going to change the fork legs so the 08 brake calipers mount without using spacers. and the fender will fit right.

I called CTR John and will be shipping it out after i take the bike apart.


The main reason for doing this is one....looks, lol
but the main reasons are I want to go back to my 310 stock rotors.

My 300mm galfer Wave Rotors I currently use are illegal for the races I run and most never noticed, but durring the last race of the season novices were protesting people left and right, lol.... so time to come clean.

The other benifit are cheaper break pads for the 08 vs the 06 caliper.

The 06 Vesrah run me $140+
The 08 Vesrahs run $90 to $110...
I can go thru about 3 sets a season.

spring to summer
6 hour endurance race eats up a set
then fresh set for the reaminder of the season.

Now the internals on 08 forks are a little bit different than the 06's but not much.
Its cheaper than getting a new set of 25mm made.

cant wait for the 2011 zx10R...im sure it will have the 38mm BP Forks on it.




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