ZXR400 Part Required

[Dal]

Does anyone happen to have a front wheel spindle and spacers for an H2 (are the common L models the same? :grin2)

[DoGbOt]

Yep, apparently all the parts are the same as the main things they changed were cosmetics all the mech's are the same from L1 to L10 ....

[Dal]

Yep, apparently all the parts are the same as the main things they changed were cosmetics all the mech's are the same from L1 to L10 ....

Thanks for the response ;) However, mines an H2 which is quite different to the L series. But some of the parts are the same. :grin2

[Lateshift]

whats this L10 he is on about anyway? ;) :D

its H1/H2 and then L1-L9 (but it went a bit pear shaped after 1999 because they remained an L9 then up until 2003 when they were discontinued.

anyway moving swiftly on :D

do the H series ones fit on the L's and vice versa Dal? (i havent checked).

we may be able to help you out, i can't promise though.

[Dal]

Hiya Mr :grin2

I'm not sure if they are same either :o

I could always nick one off of Jets but I think she might notice :laugh1

[Lateshift]

No we might have a spare spindle and nut in the shed, but having been off work for a week i will need a few days to have a check as i am back to work tomorrow :)

Ultimately it will come down to Jules as it will belong to her if we still have it ;)

[Dal]

No problem there's no rush. It's just that I'm trying to bolt as many bits on so I can see what I have missing :grin2 This bike was all in box's ;)

While I have your attention :grin3 what other brakes fit the 40?

[Perilous]

You can fit an H model wheel in an L but the left hand spacer has to be 7mm longer, so I'd assume if you made the H left hand spacer 7mm shorter the L wheel would fit. (Not sure about the speedo though, we don't use those) However if you put an H wheel in an L under heavy use due to the narrow bearing spacing it squirms around like hell (so much so I bucked one in Park at Cadwell) and makes the bike handle like sh1t.
The H discs are smaller though so you can't use H model forks with L model discs.
H model calipers will bolt on to L model fork legs and work with L discs.

ZZR D model, ZX6R F model, GPZ 900 A8 and some of the ZXR750 models run the same calipers as the H model ZXR400 which also fit on the L.

Early Gixxer 1000 six pots fit if you drill and tap them out to take the zxr 400 10mm bolts. (Have a set of those ready to go if you want to try them)
ZZR1200 and some the suzuki 600 4 pot calipers go on but you have to make a top hat style bush for the fork legs to take the calipers's 8mm bolts and to space the calipers in further to line properly with the disc.

Although they're heavier H model brake calipers are better than the L models and the pad choice is far wider as the 158 pad fitment they take is common to a vast amount of 600s and all of the models I listed earlier.

The best modification you can make to ZXR brakes though is to throw the rediculous 14 mmm master cylinder in the bin and fit a decent 5/8 one.


As far as the H being similar to the L, some model Hs have the same rear wheel as the L but other than that they're about as similiar as my riding ability is to Valentino Rossi.:grin2

[DoGbOt]

whats this L10 he is on about anyway? ;) :D

its H1/H2 and then L1-L9 (but it went a bit pear shaped after 1999 because they remained an L9 then up until 2003 when they were discontinued.

anyway moving swiftly on :D



Well it wasn't bad considereing i've never owned a kwackasaki & they dont tend to interest me much....... Riding position is just to odd for me..... plus i'm not keen on brite green (boogers)!! but i have had the missfortune of robbing bits from 1 t' other, so i was 1 number out.......

organise a shooting at dawn an i shall appear...... hehe

[Jetski]

Ultimately it will come down to Jules as it will belong to her if we still have it ;)

No problems at all :) If I have one (that isn't holding the front wheel on :D ) you can have it.

[Dal]

You can fit an H model wheel in an L but the left hand spacer has to be 7mm longer, so I'd assume if you made the H left hand spacer 7mm shorter the L wheel would fit. (Not sure about the speedo though, we don't use those) However if you put an H wheel in an L under heavy use due to the narrow bearing spacing it squirms around like hell (so much so I bucked one in Park at Cadwell) and makes the bike handle like sh1t.
The H discs are smaller though so you can't use H model forks with L model discs.
H model calipers will bolt on to L model fork legs and work with L discs.

ZZR D model, ZX6R F model, GPZ 900 A8 and some of the ZXR750 models run the same calipers as the H model ZXR400 which also fit on the L.

Early Gixxer 1000 six pots fit if you drill and tap them out to take the zxr 400 10mm bolts. (Have a set of those ready to go if you want to try them)
ZZR1200 and some the suzuki 600 4 pot calipers go on but you have to make a top hat style bush for the fork legs to take the calipers's 8mm bolts and to space the calipers in further to line properly with the disc.

Although they're heavier H model brake calipers are better than the L models and the pad choice is far wider as the 158 pad fitment they take is common to a vast amount of 600s and all of the models I listed earlier.

The best modification you can make to ZXR brakes though is to throw the rediculous 14 mmm master cylinder in the bin and fit a decent 5/8 one.


As far as the H being similar to the L, some model Hs have the same rear wheel as the L but other than that they're about as similiar as my riding ability is to Valentino Rossi.:grin2

Thanks for this Phil as always you are the font of knowledge for all things Kawasaki ;)

The main reason for changing the calipers is because the original parts are now some 18 years old and tend to be knackered needing full service kits etc (lots of money :mad:) Therefore I want something atleast as efficent as standard but newer so hopefully not needing pistons and all the seals. What about rear caliper Phil, (yes I'm one of those that does use the rear brake) TIA :D

Oh and these GSXR calipers sound interesting. What age would I be looking for?

[Lateshift]

The GSXR K1,2,3 series 4 pot Tokico calipers are the ones to look for, they were on the 600 and 750 bikes.

You might also want to consider the other option of the Nissin Fireblade 4 pot calipers too, these seemingly fit on with no modifications at all (and i have seen them on some of the clubman bikes too).

Another option is to buy a bracket from Jap4performance which allows you to use Brembo calipers ;)

[Dal]

The problem with the bracket is that as soon as you pot Brembo on anything the price goes mad :eek: It's a bit like Ohlins :grin2

They are the best and rightly demand the best prices. :)

The Blade ones sound interesting though, do you know which model / year.

I wasn't happy about having to contaminate my bike with something from a Zuki on it :grin2

Any info on a rear caliper? ;)

[Perilous]

Oh and these GSXR calipers sound interesting. What age would I be looking for?

As above.

I put a serious amount and of effort into this in 2005 when our rules changed and then again last winter when with the 2007 championship runner up when he copied my set up and we came to the conclusioon the Gixxer/ZX12 ones work the best on the ZXR.

The Nissan brakes are good but the gixxer or ZX12 ones have a much larger rear piston for hard dry braking but give also much better feel than the Nissan, IMHO.
Brembo calipers are obviously the dogs do das but the extended ali bracket that is normally used to fit them means you'll get more brake flex which you won't notice on the road but I reckon you you will on trackdays (or racing) hence I've never fitted my Brembo calipers to the ZXR. However they'll probably still give more feel than the originals.

Having said all this though newly rebuilt H model calipers with C43 pads in are good enough to totally lock the front wheel on a ZXR at 120MPh and turn the bike completly upside down when you panic brake trying to miss a braking down bike on the Brands GP straight.:grin2

Pistons and seals came aout about £160 last time I rebuilt a set of H calipers.

[Perilous]

forgot.

Rear brakes I just rebuild. theres only one piston its dead easy. I was going to put a nice little Harrison one on but it meant altering the bracket and I try to keep weverything between the #1 bike and spare as standard as possible.
Other than that dunno. They're so easy to put seals in I've never bothered looking to buy another type.

[Dal]

Phil these are for a track only setup. Your right about 160.00 for a full rebuild kit for the H calipers that's about what I paid when I built my other bike. The plan is to build this one on a more realistic budget :grin2

[Perilous]

I wasn't happy about having to contaminate my bike with something from a Zuki on it :grin2

;)


They're the same on the Kawasaki ZX12 so get ask for them then you can say they're off a Kwaka. :grin2

Nissan ones are probably your easiest bet if they go straight on like Mick says. I've only seen them used on a VFR and didn't rate them any better than rebuilt H ones so I never bothered putting them on the ZXR.

[Lateshift]

Go for the GSXR ones, they tend to go for around £60 on Ebay for the pair, a lot of the time you can pick them up for that price with stainless lines and the master cylinder/reservoir still attached ;)

As far as rear calipers go, i have yet to see a ZXR with anything other than the standard rear caliper on it?

As for the Nissin ones, i know they were fitted to the 2001 Blade, but i only saw one Clubman bike at Mallory using them, nearly all were using standard brakes apart from the likes of Phil and Ric, i think Josh Wainright was using Brembo brakes?

[Perilous]

Phil these are for a track only setup.

Check the pad fitment for the Nissans. If its not the 158 (on EBCs numbers) or another very common sports 600 fitment then deffinitely get the Gixxer ones. Even if you have to pay to have the spacers made its better as you have the choice of any type of pad race or road.

[Lateshift]

But bear in mind what they will do if standard ones do this ;) :D

http://www.djg-photography.co.uk/BH%20GP%2007/Sun/Race%2017/images/BH-GP_220707_R17-013.jpg

[Dal]

OK I'm confused now GSXR 600 / 750 4 Pots (require sleeves) or 1000 6 Pots (just need drilling and tapping)

Which am I looking for?

The 6 pots sound like the easier mod ;) which years / models.

Although the 600 / 750's are probably more plentiful

[Perilous]

The 6 pots aree the easier mod but the 4 pots are by far the better caliper and alot cheaper to get pads for.

If you want to try the 6 pots I have aset you can have but racing other clubs when we were running restrictive Supersport rules with standard L calipers and the Formula 400 guys had a craze of 6 pots I never got out braked by a 400 running 6 pots. They also used to have alot of hassle with uneven pressure form the pistons.

The 4 pots you can alter the type of pad you use to suit your how you like you're braking.
With Carbon lorriane C45s they'll lock the wheel at three figure speeds with one finger but you have to be super careful in the wet. With EBc GFA kit pads they'll do the same with two fingers and one in the wet or you can use ordinary road pads if you pefer to pull the lever harder. All with loads of initial feed back and out of all the calipers we tryed they are by far the best if you trail brake into corners.

They work exceptionally well with performance friction pads too. I personnaly don't like them but others swear by them.

[Dal]

The GSXR K1,2,3 series 4 pot Tokico calipers are the ones to look for, they were on the 600 and 750 bikes.


Ok so these are what I need :clap

"but you have to make a top hat style bush for the fork legs to take the calipers's 8mm bolts and to space the calipers in further to line properly with the disc."

Any pictures or more detail of exactly what needs to be done here.

[Dal]

These appear to be any option

http://www.zzr-international.co.uk/forum/viewtopic.php?p=34409&sid=0c07f98a29917c54b0e9ea8572ae247b

[Perilous]

Looks like its the same job to fit them though.

Basically you're using 8mm caliper bolts in a fork leg designed for ten mm bolts so you need to make four 10mm diameter bushes with an 8mm clear hole to go in the fork leg to take up the slack.
Dunno about the Nissans but the Gixxer calipers need spacing in 2mm* so they run properly in line with the disc.
You can just put a pair of washers between the caliper and the fork leg id you want I suppose if you're not going to be changing wheels if it rains etcv on your track days. It's much better to machine a bush where the washer is part of it so you can just push it in and forget about it. When you get the calipers it is obvious what you need.


*It's possible the spacing may be different for the H fork leg, not sure.

[Tark]

I have a set of restrictor plates for the ZXR if anyone is interested..

[Dal]

I have a set of restrictor plates for the ZXR if anyone is interested..

Oi get your own thread :grin2 bloody mods :rolleyes:

[Tark]

I thought that some racers might want them so rather than upgrading your brakes you might want to restrict someone elses bike so they couldn't catch you anyway..