Got my calipers put on today. Nissin 4 pots from a Honda Fireblade onto my ZZR600
Two-finger braking on a 1996 ZZR. im quite happy! also got my new shock put on and it rides so much better. im pretty sure the last shock was the original which has covered 31000miles!
hope you like
forgot to mention that i got the info on how to do this from www.zzr-international.co.uk
very good site and would thank them on there but unfortunately i cannot get registered, have tried twice
It’s great when you can do a simple upgrade from a different bike, I’ve got a GSXR front end on my SV.
It looks like you’ve got a very small swept area on your discs (the rusty inner ring not doing anything?)
I was going to say the same! :crazy:
Isn’t that quite dangerous as the braking force is being concentrated on a small area of the disc which can lead to it deforming?
Yes that’s dangerous. Those caliper mounting bolts do not look standard, might be pulling the calipers off square causing the pads to make partial contact.Something wrong either way so take it very easy on the braking until it’s fixed.
Hmm…Sounds like he sould have done a complete Fireblade fork conversion.
Thanx for the comments guys. There not standard mounting bolts as the hole on the calipers is 8mm and my kawasaki fork leg hole is 10mm i think. i had the choice of getting screws which had a shoulder to account for the missing 2mm or i could have had the calipers bored out an extra 2mm to take the original mounting ZZR mounting bolts, the reason i didnt have this done is i didnt want to take material off the caliper as i thought this would weaken it (please correct me if im wrong here as i would like to amend any problem on the bike). As for the bolts pulling the calipers off square could someone explain this to me as i dont understand.
Thanks
that should bed in with time, shouldn’t it?
bed in with time? wudnt it have happened straight away if all the pads were doing was rubbing off surface rust as its rubbed the rust off from the inner part of the disc. im quite worried about all this now as ive spent a fair bit on this and its the first time in 9 months that my brakes have felt anything like brakes but if the general consensus is that they are dangerous then i will have to sort it
i don’t know mate. looks like the calipers are not sitting squarely to the discs. strange.
from our evidence ie the picture, it looks like the pads are only making contact with the outer part of the disc…not ideal but if its better than before then thats got to be good…
however…if you have not fitted the correct bolts they will move under load…that could be very bad…and if they do move on the bolts then the bolts and surrounding area will wear…and eventually break…again not good as they will likely fail under full load…ie when you are breaking and needing to stop the hardest
I would first get the right bolts…cant be that expensive…few quid…then check if the pads are actually able to touch all of the disc itself…if they are able to and they should and they are still not touching it then there may be more issues…However I suspect they are not sitting correctly due to you not having the right bolts…so change them…and then tell us how you get on…
just thought as well…i assume you have checked that the disc itself where the rust has not cleared is not worn more than the outer edge…it may be because the previous calipers were so bad,check that too but get the bolts changed…
Just make sure that the bolts you use are ‘high tensile’
Can you see if the pads actually do make a full sweep of the disk or is the caliper spaced out further than the original ones? It could be that you need the bigger diameter disks off the Fireblade too (which i think are 320mm)
imho mate they look totally wrong, the pad biting area looks as if it over hangs towards the centre of the disc, looks like its biting on a ridge at the centre making the pads bite at a angle, leaving the rusty area in the middle. And having the smaller wrong bolts in a bigger hole wtf :w00t:
If your gona stay with these calipers, I’d un bolt the calipers and check that you have enough biting area on the disc for the size of the pads & calipers (or your pads will never wear down sq) If you do have, I’d have some caliper adaptor plates made to bring em away from the centre, which will make your pads sit flat on your disc’s, and use the right bolts…I’d also check you aint fecked your disc’s…hope that made sence 
@ Terry-Moto
thanks for the advice, i’m unsure what you mean regarding the biting area for the pads and calipers, i cannot unbolt the calipers until Saturday earliest as i don’t have any tools when i’m in Egham. however when i look up into the calipers, the pad seems to be contacting the entire disc as it should do. i have only ridden about 5 miles since having it done and didn’t brake considerably as they are much firmer than old calipers and it was damp yesterday. Could it possibly be due to uneven pad wear previous to me using them, the Fireblade calipers and pads are 2nd had (pads have a lot left on them though) and that like wlodek_1980 said that it may just bed in with time?
@ twostrokesliveon
the brakes are so much better than my old calipers already but obviously if a lot of people are telling me the same sort of thing i will try and get this sorted. silly question but how can i check for uneven disc wear (measure widths at inner/outer edges???) or could i determine this from my old pads as i have still got the old pads/calipers
As for the bolts, the bolts i have put in are not actually smaller and slipping about in the forkleg mount, its only the threaded part that is smaller to fit the Nissins.
The reason i didnt use the Kwak bolts was that the calipers would have had to be bored out a bit and rethreaded (i thought this alone would be increasing the load as i would have decreased the caliper material?)
The bolts below from l-r are new bolts (thicker through fork with thin thread for caliper), old Kwak bolts, Blade bolts.
What I ment by biting area, is as in contact area of pads to disc. If the whole of the pad face is coverd by disc space and you dont have a ridge running round the centre of the disc (thats stoppin the pad from sitting flat, this cant be the prob. 2nd hand pads mite cause this, if there that badly worn, is the inside of the disc the same ?
like i said on a quick first look the pad does seem to be covering the whole disc biting area. also i cannot see any clear ridge and cannot distinctly feel one is i run my finger from outside to inside of the disc. The new pads are 2nd hand but a lot of pad left on them, possibility that these pads are worn slightly unevenly due to the previous discs they were used on? These pads may also be sintered HH, any problem with that. When i get back from uni this eve i will check the inside of the discs aswell. Thanks alot for this help, much appreciated
I run double H’s on front and back, dont have any probs. Check em over properly when you get time and let us know how you get on :)…But take it easy 
get a striaght rule on the discs…somethign flat and look for hollows etc…and flat discs.
You maye want to take the pads out and just check that you have fitted the serping clip and the slides properly too,did you copper grease them when you fitted the pads etc…
The fact that is seems to be happening on both discs to me points to the bolts…
Any way get out there and keep checking things and let us know…
Clearly something is amiss it may be serious it may not be, but best to check everything…
Ive just taken the bike for a ride this morning and checked at a shop, it seems to be just a case of bedding in. the round trip was only about 10 miles and the section that is untouched has reduced by about half already so bedding in does seem plausible. Does anyone know of where i can get some bolts made up to my specification??
