Kawasaki Sportsbike Riders Club - Australia - Online Forum

Let me know what they come back with. The concensus on Saturday was that the regrease may prevent the piston on release moving back too far from the seal thus creating the better feel... It was much better but then again Im still relatively new to the bike!

Dropping the calipers in tomorrow. Apparently when they get hot the seals expand and hold onto the piston, so a bit of grease will allow the pistons to move as they should. Won't have a chance to test them out until Wakefield on the 27th October.

russ_2000_zx9 wrote: A full pull apart and clean every 10000kms is supposed to do the trick. Well problem here is that mine has only done 5000kms, so I reckon it might be a waste of $150.

I did the first ride day on my 07 with 1100 km on the clock, and the lever came back to the bars even then ...

I've since installed kevlar lines and an AP master cylinder, and whilst the fade has reduced, it's still there.

Will be interested to hear how long the rubber grease treatment works for ; I'll be buggered if I'm going to pull my calipers to do that very often.

Cheers,
Brian

Well I've been told that their regulars have been happy with them on the road zx10s for over 12 months. Will have to wait and see with my track bike. Some Dirtbike racers clean and regrease after every weekend racing I'm told. If I can't get more than a dozen ridedays out of it I'll be swapping callipers. Will keep you updated.

Doesn't look like it's that hard to do either, but I thought I would get it done at a shop that reckons it is the fix so that I can get a definate answer for myself. then if ok I will do it periodically myself.

Thanks Russ. I don't imagine for a second it's a hard job, but it sounds like a major pain, particualrly if a piston pops out and it needs to be re-bled.

Cheers,
Brian

Dropped the calipers off this morning and picked up in the arvo. they're back on the bike now with new rbf600 fluid in em and the lever is rock hard. Can't wait to get to the track and test em out.

Takes a mechanic an hour or so, so I imagine I would have been fiddling around for half a day. Will give it a go next time though if it works. I was recommended to replace the seals every 2nd time. But they reckon it'll be good for 10000kms or more. The service manual explains how to remove pistons etc but doesn't mention the grease which is the key.

russ_2000_zx9 wrote:Dropped the calipers off this morning and picked up in the arvo. they're back on the bike now with new rbf600 fluid in em and the lever is rock hard. Can't wait to get to the track and test em out.

Takes a mechanic an hour or so, so I imagine I would have been fiddling around for half a day. Will give it a go next time though if it works. I was recommended to replace the seals every 2nd time. But they reckon it'll be good for 10000kms or more. The service manual explains how to remove pistons etc but doesn't mention the grease which is the key.

Thanks Russ, will be very interested to see how it holds up. IMHO, the idea of replacing seals every second trackday is absolute bullshit, compelling reason to get different calipers. If it took the mechanic an hour, I'd imagine he's just pumped the pistons out a bit and greased them up, rather than popping them and replacing each seal. If I wasn't so apathetic, I'd probably even try it myself

Cheers,
Brian

I don't 't think he meant replace the seals every 2nd track day..
I'd suggest that means replace the seals every 2nd clean and grease, that would be 20,000ks.
Is that right Russ.??

What did it end up costing you for the job. Sounds like a good result.

and ahh yep I think regrease evry 10,000 and new seals every 20,000, although while they're apart it's probably worth slipping seals in anyway.

MadKaw wrote:I don't 't think he meant replace the seals every 2nd track day..
I'd suggest that means replace the seals every 2nd clean and grease, that would be 20,000ks.
Is that right Russ.??

Yeah that's right, every 2nd clean and grease, approx 20,000kms. may have to clean and regrease more often as it is a track only bike and gets used a little harder than your average road bike. Only time will tell. Reports from one guy is he's put on 20,000kms (does track days every now and then) and brakes are still great. I think the manual recommended a pull apart and clean every 4 years.

Every second track day would shit ya wouldn't it! I don't even like having to change my oil every 2nd track day, but it's cheaper than a motor rebuild so I do it.

Cost was around $130ish (charged for 1 1/2 hours labour, usually it's a 2 hour charge, but got a discount due to being a ksrc member). If it works it'll be money well spent I reckon.

Any updates russ? how do the brakes feel after what the guys at aitkens did to them?

i have a track day comming up and am thinking of doing the same

Will let you know after Wakefield on Monday (the 27th)

Hello 06-07 ZX10R Owners. I have done everything with these brakes including running a 08 ZX6R master cylinder, a older 5/8" master cylinder, a Brembo master cylinder, bleeding, back bleeding, braided lines, different brake fluids, different pads, 07 R1 calipers etc etc, and every combination there after.
Here's the drum.
The Brembo master cylinder will stop the brake fade but not the "on/off" feel of them.
The 5/8" master cylinder also stops the fade but feels very woody and also doesn't cure the on/off feel.
The ZX6R master cylinder is a reasonable improvment on the original stopping the fade, but again, not the on/off feel.
Can you see a patern? No? How about - no master cylinder will fix that awful on/off feel of the OEM brakes, only that awful fade of the lever during track days. So what to do? Well, after much swearing, money and scrapped knuckles I can confidently say it is/was the calipers causing the problem. The 4 pad calpiers are just crap. I assume only the top two pads were initally biting then all of a sudden the bottom two pads would bite, ie off..........ON!
So change the calipers from 4 pad to 2 pad. That IS the answer. I have gone for 07 CBR1000RR calipers which are the same as the originals (Tokiko) but are 2 pad. You will need to make 5mm spacers to fit to the caliper bolts (24mmx5mm with a 10mm hole) but that is it. Job done. I paid $250 for a set from the wreckers (findapart.com.au).
The change in brakes is unreal. You can actually feel the brakes come on and off and there is consistancy no matter how light or hard you brake.
If you make this mod you willl be smiling all the way to your Kawasaki Dealer where upon you will throw the original calipers through their front window whilst doing a 100m stoppie.
Guys and gals, this is the best mod you can do to your 10. Reward yourself and get to know how proper brakes should feel. Change the calipers before changing anything else. If you are unsure take a look at 08 brakes - surprise surprise - they are 2 pad.

Thanks for the info. After Wakefield I will have a couple of weeks to hunt around for a set of calipers, before heading to Phillip Island. It's a real dissapointement it took Kawasaki 4 years to sort out the brakes.

russ_2000_zx9 wrote:It's a real dissapointement it took Kawasaki 4 years to sort out the brakes.

Agreed, and it's unnaceptable that they are the only manufacturer to fark it up.

Seriously...why the fark would you buy a kawasaki again...I mean seriously.

My next bike Suzuki B-King