Author Topic: 2004 model 4-pot brake upgrade  (Read 9216 times)

Offline Centex

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2004 model 4-pot brake upgrade
« on: July 29, 2011, 05:46:36 pm »
First, thanks to Gary in CA for sharing his brake upgrade experience, thanks to Slybones 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.


View of the bracket from the wheel-side shows the basic shape



Close-up from the outside; flange head bolts through the calipers are zinc plate, class 10.9





Looks like I'll have to watch that speedo cable to ensure it doesn't hang on the corner of the caliper
Alan in Central Texas
2004 Connie COG 9476
2001 Ducati M750

Offline T Cro ®

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Re: 2004 model 4-pot brake upgrade
« Reply #1 on: July 29, 2011, 05:56:18 pm »
Very clever and "clear" idea to use the plexiglas to make your prototypes..... Looking good!
Tony P. Crochet
(SOLD) 01 Concours Winner of COG Most Modified in 2010
Ask me about a set of Stick Coils & Harness or Precision Shift Linkage for your C10 Concours

Offline Centex

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Re: 2004 model 4-pot brake upgrade
« Reply #2 on: July 29, 2011, 06:00:00 pm »
Plexiglas drills and taps easy, allowing a full bolt-up fit and alignment test.
Alan in Central Texas
2004 Connie COG 9476
2001 Ducati M750

Offline Cavediver

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Re: 2004 model 4-pot brake upgrade
« Reply #3 on: July 29, 2011, 06:28:17 pm »
Very nice This might be my next project.

Jack

Offline throb

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Re: 2004 model 4-pot brake upgrade
« Reply #4 on: July 30, 2011, 04:06:50 am »
How much better is the braking with these calipers?
'05 Concours, SISF's 2 min jet mod and exhaust cam sprocket, snarf's block off plates, risers, SS lines, fork brace, T-Cro's stick coils & shift linkage, ZZR1200 rear shock, MS rear wheel.

Offline Daytona_Mike

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Re: 2004 model 4-pot brake upgrade
« Reply #5 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.
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Offline throb

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Re: 2004 model 4-pot brake upgrade
« Reply #6 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?
'05 Concours, SISF's 2 min jet mod and exhaust cam sprocket, snarf's block off plates, risers, SS lines, fork brace, T-Cro's stick coils & shift linkage, ZZR1200 rear shock, MS rear wheel.

Offline jim snyder

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Re: 2004 model 4-pot brake upgrade
« Reply #7 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. 
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Offline Cybercraig

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Re: 2004 model 4-pot brake upgrade
« Reply #8 on: July 31, 2011, 11:55:16 am »
4 pot calipers? 320mm discs? It doesn't get any better than this! Nice job!  :thumbs:
'98 becoming more farkled up by the minute.


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Offline ATC Buckeye

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Re: 2004 model 4-pot brake upgrade
« Reply #9 on: August 01, 2011, 06:14:02 am »
I want these plates in the worst way.

enim57

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Re: 2004 model 4-pot brake upgrade
« Reply #10 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

Offline sas mayhem

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Re: 2004 model 4-pot brake upgrade
« Reply #11 on: August 02, 2011, 02:59:30 am »
09 Connie
...try to live a day without doing one of the 5 D’s....Deny, Defer, Deflect, Discount and Deceit...tougher than it sounds....

Offline throb

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Re: 2004 model 4-pot brake upgrade
« Reply #12 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    ;)
'05 Concours, SISF's 2 min jet mod and exhaust cam sprocket, snarf's block off plates, risers, SS lines, fork brace, T-Cro's stick coils & shift linkage, ZZR1200 rear shock, MS rear wheel.

Offline kzz1king

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Re: 2004 model 4-pot brake upgrade
« Reply #13 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
2010 CONCOURS
1974 Z-1

Offline 2fast

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Re: 2004 model 4-pot brake upgrade
« Reply #14 on: August 02, 2011, 08:26:55 pm »
Here's what I did. 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.
Brian in Minnesota
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