Kawasaki Concours Forum

The C10, aka Kawasaki Concours - The Original => Accessories and Modifications - C10 => Topic started by: Centex on July 29, 2011, 05:46:36 pm

Title: 2004 model 4-pot brake upgrade
Post by: Centex on July 29, 2011, 05:46:36 pm
First, thanks to Gary in CA for sharing his brake upgrade experience, thanks to Slybones (http://home.comcast.net/~slybones/Concours/connieBrakeCalipers.htm) for sharing his experience through his excellent website of Connie information, and thanks to COGger zrxmopar (Shaun) for his original 4-pot brake brackets which, based on Slybones' brake upgrade webpage, I’ve probably copied.

My bike is an '04 model.  The calipers are 4-pot Suzuki GSXR 750, 2001 to 2003 model, fresh seal kit installed.  The rotors are EBC 320mm Contour.  The pads are EBC HH.  The Galfer brake lines have been on my bike for years with the OEM calipers, not changed for this upgrade.

I started by making a full-size prototype out of Plexiglas sheet to get the locations for the holes and the shape to fit the calipers.  It took 2 trials to get the calipers perfectly aligned for the pads to track correctly on the 320mm rotors.  The prototype proved that the flat plate centers the caliper perfectly on the rotor when used on the inside face of the caliper lugs.  The bracket is tapped for the 4 bolts, the threads in the caliper lugs are drilled out to pass the M8x1.25x16 flange head bolts.  No other modification to the calipers at all.  The OEM C10 brake bolts are used at the fork leg.

The pics tell the story … the brackets are 3/16” steel plate.  Holes were done with a benchtop drill press through the Plexiglas template and hand-tapped.  I was not able to get time on a mill as I’d hoped when I started this project, so finally I just carved the brackets using abrasive cutoff and grinding disks on a 4.5 in Bosch angle grinder – very easy and quick.  A few licks with a file to round the sharp edges and a couple of coats of rattle-can caliper paint on the brackets to finish.

(http://i1188.photobucket.com/albums/z419/mypicnow/connie%20brakes/insideviewmounted.jpg)
View of the bracket from the wheel-side shows the basic shape


(http://i1188.photobucket.com/albums/z419/mypicnow/connie%20brakes/mounted.jpg)
Close-up from the outside; flange head bolts through the calipers are zinc plate, class 10.9


(http://i1188.photobucket.com/albums/z419/mypicnow/connie%20brakes/rtwheel.jpg)

(http://i1188.photobucket.com/albums/z419/mypicnow/connie%20brakes/ltwheel.jpg)
Looks like I'll have to watch that speedo cable to ensure it doesn't hang on the corner of the caliper
Title: Re: 2004 model 4-pot brake upgrade
Post by: T Cro ® on July 29, 2011, 05:56:18 pm
Very clever and "clear" idea to use the plexiglas to make your prototypes..... Looking good!
Title: Re: 2004 model 4-pot brake upgrade
Post by: Centex on July 29, 2011, 06:00:00 pm
Plexiglas drills and taps easy, allowing a full bolt-up fit and alignment test.
Title: Re: 2004 model 4-pot brake upgrade
Post by: Cavediver on July 29, 2011, 06:28:17 pm
Very nice This might be my next project.

Jack
Title: Re: 2004 model 4-pot brake upgrade
Post by: throb on July 30, 2011, 04:06:50 am
How much better is the braking with these calipers?
Title: Re: 2004 model 4-pot brake upgrade
Post by: Daytona_Mike on July 30, 2011, 08:15:13 am
How much better is the braking with these calipers?
The braking improves by a factor of  :pukeface: 'Blah!' to 'WOW! :thumbs:' 
 It is not just the calipers, it is the calipers and going from 300mm to 320mm.
Title: Re: 2004 model 4-pot brake upgrade
Post by: throb on July 31, 2011, 04:50:53 am
Sweet, is there anyone making the adapter plates yet or is this a figure it out yourself deal?
Title: Re: 2004 model 4-pot brake upgrade
Post by: jim snyder on July 31, 2011, 11:39:32 am
Sweet, is there anyone making the adapter plates yet or is this a figure it out yourself deal?

We are still working on it. 
Title: Re: 2004 model 4-pot brake upgrade
Post by: Cybercraig on July 31, 2011, 11:55:16 am
4 pot calipers? 320mm discs? It doesn't get any better than this! Nice job!  :thumbs:
Title: Re: 2004 model 4-pot brake upgrade
Post by: ATC Buckeye on August 01, 2011, 06:14:02 am
I want these plates in the worst way.
Title: Re: 2004 model 4-pot brake upgrade
Post by: enim57 on August 02, 2011, 02:47:43 am
It's about time someone made a neat & simple bracket for this. Very similar to the ones I make for the 86-93 models. Well done!

Regards, Russell
Title: Re: 2004 model 4-pot brake upgrade
Post by: sas mayhem on August 02, 2011, 02:59:30 am
We are still working on it.

 :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn: :popcorn:
Title: Re: 2004 model 4-pot brake upgrade
Post by: throb on August 02, 2011, 03:19:01 am
I'm certain you can sell a ton of them...in fact, if there's a waiting list, put me on it!   :P    ;)
Title: Re: 2004 model 4-pot brake upgrade
Post by: kzz1king on August 02, 2011, 07:22:35 pm
So I am looking for info on the 4 pot mod to the older Connies. Cost? Parts needed? Thanks
Title: Re: 2004 model 4-pot brake upgrade
Post by: 2fast on August 02, 2011, 08:26:55 pm
Here's what I did. http://forum.cog-online.org/index.php/topic,28138.0.html (http://forum.cog-online.org/index.php/topic,28138.0.html) You can see em in Vermont in a few days if you are going.
Title: Re: 2004 model 4-pot brake upgrade
Post by: jim snyder on August 02, 2011, 09:18:49 pm
Here's what I did. [url]http://forum.cog-online.org/index.php/topic,28138.0.html[/url] ([url]http://forum.cog-online.org/index.php/topic,28138.0.html[/url]) You can see em in Vermont in a few days if you are going.


Very nice 2F. Where did you get the rotors and what brand are they? I am fixing to fabricate some of these brackets very soon, as soon as the temperature gets below 100 here in Texas, which should be about november.
Title: Re: 2004 model 4-pot brake upgrade
Post by: 2fast on August 03, 2011, 07:52:07 am
Jim,
The rotors are Chinese from these guys http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681 (http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681) and are made for a Yamaha YZF R7. They fit the older model center hole, but the mounting holes need to be drilled out one size.  I don't have many miles on them yet, but by the time I get back from Vermont they will be fully tested.
Title: Re: 2004 model 4-pot brake upgrade
Post by: jim snyder on August 03, 2011, 10:25:38 am
Jim,
The rotors are Chinese from these guys [url]http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681[/url] ([url]http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681[/url]) and are made for a Yamaha YZF R7. They fit the older model center hole, but the mounting holes need to be drilled out one size.  I don't have many miles on them yet, but by the time I get back from Vermont they will be fully tested.


So they will only fit the older model front wheel ?
Title: Re: 2004 model 4-pot brake upgrade
Post by: 2fast on August 03, 2011, 03:38:29 pm
Yes, but I would be surprised if they don't make em for the new style.

edit to add:

http://cgi.ebay.com/Front-Brake-Disc-Kawasaki-ZG1000-ConCours-94-06-/250612779613?pt=UK_Motorcycle_Parts&hash=item3a59af8a5d#ht_1359wt_952 (http://cgi.ebay.com/Front-Brake-Disc-Kawasaki-ZG1000-ConCours-94-06-/250612779613?pt=UK_Motorcycle_Parts&hash=item3a59af8a5d#ht_1359wt_952)
Title: Re: 2004 model 4-pot brake upgrade
Post by: Centex on August 03, 2011, 04:01:29 pm
Brian / Jim - I notice that the rotors you linked above are replacement for the 94-06 Connie, so they are 300mm, not 320mm.

If you want 320mm for exact fit on the 94-06 Connie, look for replacements for the following bikes (among others) which came with 320mm stock and the correct bolt pattern / offset:

93-01 ZX11
00-03 ZX12
Title: Re: 2004 model 4-pot brake upgrade
Post by: jim snyder on August 03, 2011, 09:17:21 pm
Brian / Jim - I notice that the rotors you linked above are replacement for the 94-06 Connie, so they are 300mm, not 320mm.

If you want 320mm for exact fit on the 94-06 Connie, look for replacements for the following bikes (among others) which came with 320mm stock and the correct bolt pattern / offset:

93-01 ZX11
00-03 ZX12

The 94 thru 06 rotors are 300 m/m, 320 would be over size for the stock brackets
Title: Re: 2004 model 4-pot brake upgrade
Post by: 2fast on August 03, 2011, 09:31:11 pm
The 94 thru 06 rotors are 300 m/m, 320 would be over size for the stock brackets

True true. I think the better upgrade for the newer models would be just a better caliper.....300 is already a decent size. In my case, the improvement was pretty huge going from a stock 270mm with a single pot to 320mm with 4 pots.
Title: Re: 2004 model 4-pot brake upgrade
Post by: jim snyder on August 04, 2011, 02:31:00 pm
True true. I think the better upgrade for the newer models would be just a better caliper.....300 is already a decent size. In my case, the improvement was pretty huge going from a stock 270mm with a single pot to 320mm with 4 pots.

I agree. The biggest improvement is definitely the caliper. I also used the GSXR-750 Tokico calipers with the stock 300m/m rotors. I probably wouldn't go to the 320m/m rotors unless/until my 300's go bad. 
Title: Re: 2004 model 4-pot brake upgrade
Post by: enim57 on August 06, 2011, 07:19:09 am
It's the calipers that make the biggest difference, increasing from 300 to 320 discs will only give a 6.7% increase (torque = force x radius). When I did the upgrade for the earlier models I calculated there is 33% more pad area and 133% more piston area.

So I am looking for info on the 4 pot mod to the older Connies. Cost? Parts needed? Thanks


If you're using the stock size discs of 270mm diameter I can supply brackets to suit Nissin 4 piston calipers, I don't have any in stock at the moment though. See link below:
http://gtr1000.yuku.com/topic/3638/4-piston-brake-calipers (http://gtr1000.yuku.com/topic/3638/4-piston-brake-calipers)

Regards, Russell