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Date Posted: 12/07/04 19:20:15
Author: Dan
Subject: ZZR600 Brakes - The Battle is Won!

Finally, after some time, I have finally sorted my brakes on my ZZR600E!!

A brief outline, I bought my Zed last year for a bargain price, £1000 for a 1995, 12500 mile example. The brakes seemed to bind a little, but I was not too worried - my first bike, so all I cared about was riding it - all through the winter!!

As you can guess, ths did nothing to ease the binding, which progressed to the back brake, which then seemed to lose any stopping power.

I decided to attempt to replace the seals, after getting details from this site I bought a set. I then attempted to remove the pistons from the front calipers, by removing the pads and pumping them out as far as possible. Great, I thought... until I tried to remove the bloody pistons!! 6 of the front ones were stuck solid, I tried everything (including mole grips!), and even took them to a bike garage, but they are stuck solid. The dust seals on all 8 pots disintegrated years ago, and looking at the removed bores, there was corrosion in the bore as well as in the seal seat. Bugger.

My efforts them moved to the rear caliper - I was over the moon when I found that this was also stuck solid, and pumping the pedal did not produce any movement in the piston whatsoever! No wonder I had concerns about the bikes braking peformance!!

I have now remedied this, as some cost, but I didn't really have any option - 2 pattern replacement front calipers and 1 used rear. The fronts came with new pads, the rear with hardly-used original pads.

I also decided to renew the front brake lines, with 2 braided hosed going directly from caliper to master cylinder. In my opinion, this is well worth doing, and makes bleeding the brakes so much easier - I used less than a litre of brake fluid to bleed both the front and back brakes thanks to these! I had bled the front brakes before with the standard set-up and never got anything near to the firm lever I have now! The only slight downside is that the lines do not route as cleanly as the standard lines, but it's a small price to pay...

Overall it has cost me £410 to solve this (£50 for the lines, £320 for the front calipers and it needed doing!

Lessons learned? Keep the calipers clean - I intend to use brake cleaner in the winter months, as well as replacing the seals the minute I notice any wear. An annual strip-down is on the cards. 1 other thing - next time, I'm going to buy a Honda!!

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