Kawasaki Sportsbike Riders Club - Australia - Online Forum

Gday, riding to work this mornign my front brakes went soft; I was able to pump them as though there was air in the lines and they felt better except it sounded like I had no pads left. I pulled over to check what the problem was and the outer brake pad had dislodged and was consequently only being pushed by one piston. Any one have any ideas what may have caused this. I have not had the caliper off for 5000kms and that was just to change the front tyre.

Thanks
Ben

Sounds like the caliper needs a rebuild.

Last time I needed this done, I just bought a replacement from a wrecker for $40 as I was in a hurry.

As I am not an expert I am not doubting you but what makes you say this? Any idea how much a rebuild would cost - second hand maybe someone elses problem

As I am not an expert I am not doubting you but what makes you say this?

1. Brakes not working
2. Caliper seen to be operating incorrectly
3. Caliper should be serviced/repaired/replaced

I am not sure I can go into any other detail!?

Brakes work like this:

1. Squeeze lever
2. Lever activates piston that displaces brake fluid in reservoir.
3. Fluid travels down hose to caliper
4. Fluid displacement at caliper causes caliper to squeeze brake pads <--- fail here
5. Bike slows down

As the fluid is obviously getting to the caliper, and it is just not operating correctly, it is reasonable to assume that this is where your problem lies.

Any idea how much a rebuild would cost - second hand maybe someone elses problem

Assuming the pistons aren't badly corroded (as this is uncommon) then it will just need new rubber seals which cost about $10, plus 1-2 hours labour to remove, rebuld & refit the caliper and bleed the brakes, and about $10 for brake fluid. If your brake pads are worn unevenly (probably) you will need new ones. They are about $30.

$10 + (2x$60) + $10 = $140.

If you have twin rotors on the front (not 100% sure if this was available on the ZZR250, it was definitely available on the GPX250) then they should both be done at the same time, which will increase the cost.