bolts to fit GSX-R Tokico 4pots

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Charles
zxr400 oc member
zxr400 oc member
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Joined: Sun Aug 28, 2011 9:16 pm
My Bike: ZXR400, TL1000R
Location: Fourques, France

bolts to fit GSX-R Tokico 4pots

Post by Charles » Fri Nov 27, 2015 5:00 pm

Sorry,
I checked the FAQ first, but I couldn't find an answer.

The GSX-R Tokico 4pots can not be fitted plug and play as they use much smaller bolts than the original Kawasaki calipers do.

Are there bolts that fit these calipers tot the ZXR fork plug and play or do I need to have some spacers made up to make the original Kawasaki ones fit?

I'd prefer not to use spacers as they might get me in trouble with the TUV over here.

Thanks very much,

Charles
1977 DT400
1986 GSX-R750
1993 ZXR400
1999 TL1000R

Zaphod
Posts: 6
Joined: Thu Nov 19, 2015 6:37 am
My Bike: zxr4, sc48, rn04, xv1900

Re: bolts to fit GSX-R Tokico 4pots

Post by Zaphod » Sat Nov 28, 2015 11:37 am

widen the holes in the caliper ! 1mm more radius is not critical

or gimme a PN ;)

greetz
zaphod

Zaphod
Posts: 6
Joined: Thu Nov 19, 2015 6:37 am
My Bike: zxr4, sc48, rn04, xv1900

Re: bolts to fit GSX-R Tokico 4pots

Post by Zaphod » Sat Nov 28, 2015 11:39 am

or use helicoils in the fork's screwholes

ManxMan
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Joined: Tue Mar 04, 2014 11:35 am
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Re: bolts to fit GSX-R Tokico 4pots

Post by ManxMan » Sat Nov 28, 2015 2:08 pm

Zaphod wrote:or use helicoils in the fork's screwholes

I don't think that would help at all

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RedexRobB
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Re: bolts to fit GSX-R Tokico 4pots

Post by RedexRobB » Mon Nov 30, 2015 6:39 pm

sleeves need to be fitted, you can pick these up on ebay.

Alternative could be to use a bolt with the correct thread but a thicker shaft to remove the need for the sleeve.

Tinman
Posts: 39
Joined: Mon Aug 04, 2014 9:30 pm
My Bike: Kawasaki zxr 400

Re: bolts to fit GSX-R Tokico 4pots

Post by Tinman » Wed Dec 02, 2015 6:13 pm

I have gsxr calipers fitted to my bike, first of all with the original gsxr bolts using the spacers mentioned earlier, which I found doing a simple search on eBay. Then afterwards when I managed to screw up the threads in the calipers because I used thread locker and when I later tried to remove the calipers I screwed the threads up. If you do it this way I would recommend not using thread locker on the bolts!

So in the end I had to drill and tap the calipers to accept the larger 10mm zxr bolt, which I think has worked out better in the end.

If you do decide to drill and tap the threads don't buy a cheapo set of taps from eBay as they are shite and will not work. You need an M10x1.25 tap to match the thread of the larger zxr bolt thread.

Tinman
Posts: 39
Joined: Mon Aug 04, 2014 9:30 pm
My Bike: Kawasaki zxr 400

Re: bolts to fit GSX-R Tokico 4pots

Post by Tinman » Wed Dec 02, 2015 6:53 pm

Just to add at after I had my gsxr calipers fitted and working, I found that the size of the master cylinder bore wasn't well matched to the size of the Pistons in the caliper and as a result of this the braking power was very strong but there was a great deal of travel at the brake lever. So to solve this problem I also fitted a gsxr master cylinder and now the brakes are excellent.

Zaphod
Posts: 6
Joined: Thu Nov 19, 2015 6:37 am
My Bike: zxr4, sc48, rn04, xv1900

Re: bolts to fit GSX-R Tokico 4pots

Post by Zaphod » Thu Dec 03, 2015 2:03 pm

i will convert my calipers into sc50 ones incl master cylinder...same issue..

8mm screwholes in the caliper..
we will widen them to 10mm and use cnc spacers (aproxx <2mm, friend of mine will make them) to match the disks middle with the caliper
1hr work ( check clearance inside the calipers/disks...mines are fine at >1mm gap between outer ring of the disks and the caliper)

cheerio
zaphod

Charles
zxr400 oc member
zxr400 oc member
Posts: 20
Joined: Sun Aug 28, 2011 9:16 pm
My Bike: ZXR400, TL1000R
Location: Fourques, France

Re: bolts to fit GSX-R Tokico 4pots

Post by Charles » Thu Dec 03, 2015 2:55 pm

Thanks everyone! I adapted the GSX-R calipers to take the Kawasaki bolts.
I now fitted them and together with new stainless hoses they work a treat.
Got now quite some travel of the brake lever, so in time I will fit a GSX-R one as well,
but it is still a huge improvement over the old calipers (each with 2 stuck pistons) and the old rubber hoses.


Charles
1977 DT400
1986 GSX-R750
1993 ZXR400
1999 TL1000R

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