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Date Posted: 14/07/04 21:19:36
Author: Kimey
Subject: Re: ZZR600 Brakes - The Battle is Won!
In reply to: Dan 's message, "ZZR600 Brakes - The Battle is Won!" on 12/07/04 19:20:15

And I thought only I had problems with brakes!!

By the way I had a NC30 and whilst bleeding was easier, bloody dust seals go just as quick!!

Surely there is a better way of doing it than crappy dust seals that last 5 mins

PS Where did you get your pattern calipers from?




>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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