Brake FAQ, please check here first

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banner001
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Brake FAQ, please check here first

Post by banner001 » Thu Aug 23, 2012 3:50 pm

Brake FAQ's.
0. My # has broken/ i am missing part #/where can i buy #?
Cradley kawasaki 01384 633455 (http://www.cradleykawasaki.co.uk), or any other kawasaki dealer.

1. What other brakes are compatible with my ZXR 400?
Compatible callipers may require slight modifications to fit, or sleeves on the bolts, nothing too problematic (search for GSXR, plenty of posts on here).
Front Callipers:- (mounting points need to be 62mm apart, OEM H and L are interchangeable with different pads - viewtopic.php?f=121&t=6915)
L/H models - ZRX400 post ’98 (viewtopic.php?f=55&t=3775&hilit=1989)
L/H models - CBR600 FX (viewtopic.php?f=1&t=8908&start=15)
L/H models - GSXR600 K1/K2/K3, GSXR750 K3 (viewtopic.php?f=121&t=14128), GSXR1000 K1/K2 (viewtopic.php?f=55&t=8559)
L/H models - Possibly ZZR1000, ZXR750H, ZX6R F1/F2, ZZR600D, CBR900 (viewtopic.php?f=121&t=2836), SV650, SV1000 (viewtopic.php?f=121&t=13908)

Rear Callipers :- (mounting points need to be 75mm centre-to-centre, and ~59mm +/- 2mm from torque arm mounting bolt to closest calliper bracket mounting point, centre-to-centre), about 80% sure that H and L rear's are the same.
L1-9 - GSXR 1000 K1/K2 (viewtopic.php?f=121&t=13834)

2. Will Radial callipers fit?
Radial callipers WILL NOT FIT unless you have changed the fork lowers to ones with radial mountings.

3. I want to change my master cylinder (MC), what will fit?
ZXR 400 handlebars are a standard 22mm (7/8") diameter, suspected that most non-radial MC's will fit, radial MC's may foul the water temperature dial as they project further 'out' than the stock MC. (viewtopic.php?f=121&t=10681)
Front:-
Possibly ZX10r, Brembo.

Rear:-
L1-9 - R1 2007/2008 Brembo (viewtopic.php?f=121&t=13937)

4. Can I change my brake lines?
Yes, do it now! The OEM rubber lines fitted to the bike have a lifetime of about 4 years, so you are advised to change them as soon as possible. General consensus is to upgrade to steel braided lines. There are several manufacturers including HEL (http://h-e-l.co.uk/) and Goodridge (http://www.goodridge.net). The stock zxr braking system uses a splitter above the mudguard, this is a 3-line system, or you can go for a 2-line system that removes the splitter, personal choice as to which you want (no difference in brake feel), although the 2-line saves some weight (~120g) and is easier to bleed (viewtopic.php?f=121&t=11175).

5. What brake pads can I fit (to standard callipers)?
(viewtopic.php?f=121&t=12502)
L1-5 - EBC - Front: FA180HH, Rear: FA161HH
L1-5 - Ferodo - Front: FDB741, Rear: FDB338
L1-5 - Carbone Lorraine - Front: 2363 XBK5, Rear: 2282 RX3
L1-5 - Vesrah - Front: VD-433JL, Rear: VD-327/2JL
L1-9 - Brembo - Front: 07KA1406, Rear: 07KS05SP
H1-H2 Brembo - Front: 07KA1306, Rear: 07KS05SP
H1-H2 - EBC - Front:EBC FA158, EBC FA158HH

6. What are the differences between H and L model callipers/discs?
H model discs are 300mm, L model discs are 310mm. Caliper mounting bolts are the same distance at 62mm, but H model callipers can take thicker pads (viewtopic.php?f=121&t=12986). H model uses 32/30mm pistons, L model uses 30/28mm both seem to be nitride coated (viewtopic.php?f=121&t=12976).

7. My pad retaining pins are jammed-in solid, what can I do?
You have 4 realistic options (viewtopic.php?f=121&t=13624):-
a) Apply heat to the calliper to expand the metal around the pin, try to not heat the pin too much.
b) Clamp mole grips to the pin and try to drift them out with a hammer, also you can try to cut a slot in the retaining pin and drift it out with a hammer and nail.
c) Drill the pin out.
d) Buy a new calliper

8. I need new pistons in my callipers, what do I need to do?
There are several guides as to how you go about removing your pistons (viewtopic.php?f=121&t=9206), replacing the dust seals etc.

9. My brakes feel like they are snatching, hard then soft, what's wrong?
Usually this is the sign of a bad master cylinder, either replace internals or replace the whole master cylinder assembly (viewtopic.php?f=121&t=14067).

10. I want to fit new brake disks, what will fit?
Front:
H2 - ZX6R/ZX600 F1-F3 '95-'97 (viewtopic.php?f=121&t=14511)
L-model - Galfer (http://www.ebay.co.uk/itm/Galfer-Wavy-F ... 23208a91de), Blackshadow (viewtopic.php?f=121&t=12678). Possibly any 310mm kawasaki disks ZZR/Zephyr/ZRX (viewtopic.php?f=121&t=12552).

Rear:
L-model -Galfer, EBC (), Breaking (http://www.braking.com/catalogue/dettag ... lo=KW15RID) are two manufacturers who will supply these. Brake disk needs to be of the following specification to fit a standard breaking setup.

11. What brake fluid should i use, how often does it need replacing and when should i bleed my brakes?
You need to use DOT3 or (recommended) DOT4. Once you decide on a grade/brand do a full flush of the brake system with your preferred brake fluid then ONLY stick with that fluid (viewtopic.php?f=121&t=13370). Different brake fluids/manufacturers have slightly different formulations and mixing will affect breaking (they form azetrophs with boiling points lower than either previous fluid). Your brake systems need a full change of fluid every 2 years, ideally every year. Brakes will need bleeding on a periodic basis, as and when they feel worse than they used to, or every 4-6 months, whichever is first. Brake fluid should be free of air bubbles, free of dirt, should be kept sealed at all times to prevent ingress of water vapour and should be a clear-to-slightly-yellow colour (viewtopic.php?f=121&t=12226).

12. What braking items will need general maintenance performing, and at what interval?
L/H models:
Brake pad thickness/wear - every 3000 miles
Brake fluid level - every month
Brake fluid change - every 2 years/12,000 miles (whichever comes first)
Brake MC cup and dust seal - every 2 years
Caliper piston oil and dust seals - every 2 years
Brake light switches - every 3000 miles

13. My brakes feel like they are pulsating, what is causing this?
Likely causes are a warped disk (viewtopic.php?f=121&t=13647) although the causes of this can be anything from disk having been excessively raced (high temperatures) to duff calipers, bent forks etc...diagnose the underlying problem then replace the disk. It is possible, but not recommended, to have the disks skimmed to remove and high spots, but best to buy new replacements (viewtopic.php?f=121&t=12647).

14. I want to change my brake/clutch levers to something other than OEM, what is available?
L models - Pazzo brake levers will fit, unsure as to the clutch levers (viewtopic.php?f=121&t=12121).

15. Is there anyway to lose the torque arm at the rear?
Yes, rodger middleton makes rear caliper mounts for race bikes that replaces the torque arm with a much shorter one.
Last edited by banner001 on Sun Mar 03, 2013 5:51 pm, edited 17 times in total.
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banner001
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Re: Brake FAQ, please check here first

Post by banner001 » Thu Aug 23, 2012 3:55 pm

This is going to be an ongoing thread, am trying to collate everything on here so far and check it against everything else known about the zxr 400 brakes to try and get a good resource to use in future.
I am not including info for the J and M models as 1. cant really find out that much and 2. so rare that most people dont have one, and the parts on them are usually better that H/L spec so no need to change...

If anyone can add to this, list it here, i will try to add links to existing threads for people as and when i can.

Notes H/L means H1-2 and L1-9, L# means some L models, L1-5 means definitely L1-5 maybe others.

Enjoy...
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Re: Brake FAQ, please check here first

Post by Tirpitz » Fri Aug 24, 2012 10:52 pm

Excellent. Hopefully this will cut down some of the repetitive questions.

A few suggestions for additional info -

1. Replacement of brake lines - the service recommended replacement lifetime for the original OEM brake hoses is 4 years. So for the vast majority of bikes it is not a question of 'can I replace my brake lines?' as 'you need to replace your brake lines'. Replacing with OEM rubber lines is madness, braided are better and last virtually for ever.

2. Brake fluid does not last forever. Not only does it slowly absorb moisture and therefore becomes less effective but it becomes corrosive, wrecking the calipers, pistons and seals. It should be replaced every two years. It's dirt cheap and it's an easy job. If you neglect it you can look forward to rebuilding your brakes, which is far more expensive and a right PITA.

3. Kwak also recommend replacing the master cylinder cups and dust seals, plus the caliper piston seals every two years, although IMHO this is overkill. If you don't have a problem then personally I wouldn't do it, however you should be aware that these are service items so if you do have a problem this is an area which may need attention.
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Re: Brake FAQ, please check here first

Post by banner001 » Sun Aug 26, 2012 12:40 pm

thanks tirpitz, info added.
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Re: Brake FAQ, please check here first

Post by BigB » Fri Aug 31, 2012 11:03 pm

H model brake pads EBC FA158 - same as Suzuki SV650 and some other gsxr bikes

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Re: Brake FAQ, please check here first

Post by Damian120 » Sat Mar 22, 2014 2:17 pm

Don't suppose it would be relevant to add minimum disc thickness? Unless this changes per manufacturer. Could be useful information, especially for discs that are either original (such as mine) or just a direct replacement :smt001
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Re: Brake FAQ, please check here first

Post by CaNsA » Sat Mar 22, 2014 2:49 pm

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Master cylinder

Post by Smousley1995 » Tue Oct 07, 2014 7:47 pm

Is the L model and H model master cylinder the same?
If not, what's the difference to tell between the two?
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Re: Brake FAQ, please check here first

Post by zimm » Tue Oct 07, 2014 7:52 pm

L model is 14 mm
h is 5/8th's. . which is about 15.8 mm iirc.

H gives a firmer feel
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Re: Brake FAQ, please check here first

Post by Smousley1995 » Tue Oct 07, 2014 8:35 pm

zimm wrote:L model is 14 mm
h is 5/8th's. . which is about 15.8 mm iirc.

H gives a firmer feel
Are they interchangeable between the two bikes? The same sized threads for the banjos?
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Re: Brake FAQ, please check here first

Post by zimm » Wed Oct 08, 2014 7:39 am

Yep
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Re: Brake FAQ, please check here first

Post by Smousley1995 » Wed Oct 08, 2014 12:04 pm

Cheers :excited
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