Hello,
I recently put 320mm floating discs from a FZR1000 on my '75 XS650 and I thought that others might be interested in some details...
My XS was born with two discs in front but the brake master and spongy rubber hoses made braking a very "interesting" thing. Also my fork seals were bust so I started assembling a new front end:
- 35mm fork legs from a later XS (the whole front end is a direct swap with aftermarket roller bearings)
- brembo brake master (has brake switch built in)
- FZR 1000 320 mm brake discs
- Two 6mm thick aluminium spacers to go behind the discs
- two SV650 two-piston brake calipers
- two steel-braided brake lines (directly from master to calipers)
- caliper spacer made out of 6mm high grade aluminum
all parts are relatively easy to source from ebay...
1. Give a brake disc to a machine shop and have them make a round spacer with holes corresponding to the disc. If you have a lathe, you may be able to make them yourself...
2. Put front wheel back on with your new spacers and discs (in the picture you can see my plywood mockup)
3. If you have a 35mm fork on, chances are that you only need a 6mm thick piece of high-grade aluminium and a printer. Print out the template I've attached (remember that your printer should not "scale automatically") and use it to mark the 4 holes
Download template: http://www.mediafire.com/?r8sqs12u8vocpib
4. Drill/cut out the spacer. The two holes for the fork leg should have a 8,5 mm diameter. Then cut a 1.50 thread for a 10mm bolt in the two holes. The calipers are mounted on a floating bracket with threaded holes so the spacer just needs two 10mm holes for the bolts to pass through here.
5. test-mount to see that everything fits
6. put on your sportsbike master cylinder... any 90's/early 2000's sportbike bike master will do.
7. Bolt your brake lines up and bleed the system... takes 5 minutes with this cheap but amazingly effective compressed air gizmo: http://s7d4.scene7.com/is/image/GriotsGarage/35714?$detail$
8. ride and enjoy 2-finger braking with lots of feel!
(only one the left caliper is connected in this photo as I managed to squeeze one in the bike lift :-(
I recently put 320mm floating discs from a FZR1000 on my '75 XS650 and I thought that others might be interested in some details...
My XS was born with two discs in front but the brake master and spongy rubber hoses made braking a very "interesting" thing. Also my fork seals were bust so I started assembling a new front end:
- 35mm fork legs from a later XS (the whole front end is a direct swap with aftermarket roller bearings)
- brembo brake master (has brake switch built in)
- FZR 1000 320 mm brake discs
- Two 6mm thick aluminium spacers to go behind the discs
- two SV650 two-piston brake calipers
- two steel-braided brake lines (directly from master to calipers)
- caliper spacer made out of 6mm high grade aluminum
all parts are relatively easy to source from ebay...
1. Give a brake disc to a machine shop and have them make a round spacer with holes corresponding to the disc. If you have a lathe, you may be able to make them yourself...
2. Put front wheel back on with your new spacers and discs (in the picture you can see my plywood mockup)
3. If you have a 35mm fork on, chances are that you only need a 6mm thick piece of high-grade aluminium and a printer. Print out the template I've attached (remember that your printer should not "scale automatically") and use it to mark the 4 holes
Download template: http://www.mediafire.com/?r8sqs12u8vocpib
4. Drill/cut out the spacer. The two holes for the fork leg should have a 8,5 mm diameter. Then cut a 1.50 thread for a 10mm bolt in the two holes. The calipers are mounted on a floating bracket with threaded holes so the spacer just needs two 10mm holes for the bolts to pass through here.
5. test-mount to see that everything fits
6. put on your sportsbike master cylinder... any 90's/early 2000's sportbike bike master will do.
7. Bolt your brake lines up and bleed the system... takes 5 minutes with this cheap but amazingly effective compressed air gizmo: http://s7d4.scene7.com/is/image/GriotsGarage/35714?$detail$
8. ride and enjoy 2-finger braking with lots of feel!
(only one the left caliper is connected in this photo as I managed to squeeze one in the bike lift :-(
