Change and restoration of the brake system

Discs, hoses, brake fluid, pads, calipers and pistons

Saga of the restoration of the sports car Kawasaki ZX6R 636 model 2002: 22th episode

Obviously since the bike was not rolling, so I could never brake other than pushing. But if you look closely at it the area of ​​the side of the brake system, there is also "damage". At the very least, work on cleaning everything.

And braking isn't just pads. Everything should be checked from the lever or pedal that triggers the braking, to discs, calipers, pistons and pads, cables, rods and other hoses.

Old hose and new brake hose

If the aircraft type hose is damaged, I already have a replacement.

Finally, substitutes: I change them. But even if I do this part, I know I can go further in rehab. Much further.

Brake discs, on the other hand, have little wear, but the pads wear out 2/3. It may still go on. Moreover, I slow down a little. Very little. Suffice it to say that for me it is a long-term investment to replace them. However, I will do it to start again on a good basis.

Judgment night

We don't laugh with braking, especially on a sports car of this level and with 6 pistons in the front calipers. Replacing the armored hoses in any case includes a complete cleaning of the brake system. Evil for good! Extra charge too. And M… de. Anyway, the motorcycle is expensive in consumables, whether we talk about it, whether it is at this time T or later, I will have to go there. Went. I go for Carbon Lorraine gaskets, sorry CL Brakes, more precisely in the road range of the French manufacturer. Kokoriko!

Well, as long as I do this and have the calipers cleaned of fluid, I decide to replace the piston seals and clean them completely.

Cleaning the brake calipers before rebuilding

This will take care of me even more since I have never touched on this in the past. I usually only change the brake fluid and pads. From what I can see, the front brake master cylinder (which is controlled by the brake lever) doesn't need a fresh shot.

Master cylinder looks correct

The lever also doesn't seem to have any reluctance or spongy response. Otherwise, I would also have fallen in love with the repair kit for about 20 euros. The future will show if there is still a future ...

Brake redesign: possible solutions

When you want to return momentum to your braking system, there are several paths and just as many solutions. The braking system is quite long and includes many elements. Therefore, we can:

Choose used or new parts, go back to original brake system, in this case 2-piece hose with splitter.

• The cost of new original brake hoses: only 182 euros, the total amount is almost 300 euros (banjo, seals, dispatcher, etc.).
• The cost of a complete brake system with consumables in good condition and sometimes under pressure: approx. 100 euro.
• Cost of new adaptable aircraft-type front brake hoses (2 hoses): approx. € 75 per set, corrugated, with seals.
• Cost of used hoses: not found at the time of my search. Attention to the size and assembly of the banjo, as well as the center distance of the attachment with the homula.

Choose used or new parts and replace the master cylinder to adapt the radial and large diameter and therefore more efficient. For example, PR19 in Brembo.

• Cost of a new Brembo master cylinder: around 250 euros
• Price for a pre-owned Brembo master cylinder: approx. 150 euros

Convert the attachment of the axial to the radial stirrups and start again with the radial stirrups, which are more powerful in theory and offer a better feel.

• Axial / Radial Conversion Kit Cost:
• The cost of the new radial support: from 500 euros ... each.
• Cost of used radial caliper with spacers (center distance. 108 mm): from 250 euros per pair (Nissin or Tokico)

While you are doing this, choose a center distance of 100mm, if possible, instead of Japanese 108mm. Cause? Sometimes it is much cheaper. On average, 2-3 times cheaper.

Brake system restoration program:

• Cleaning and replacing brake fluid
• Replacing brake hoses and hoses
• Brake pad replacement
• Repair of brake calipers

Selected solutions and total budget for the brake repair operation:

• Goodridge front brake hose set (fastened hoses + screws + washers / shims): approx. 80 €

BST Aviation Hose Kit

• Brake pads: about 40 euros for a set of front pads. It will take two, or 80 euros.
• Brake Caliper Repair Kit: Approx. 60 €

Caliper referencing kit

• Brake fluid: from 9 euros

Total: 230 euros for a completely redesigned front braking. You have to add 30 euros to repeat the seals of the rear brake calipers. We are at 260 euros. Ouch. When I can, I negotiate small rates for the kits and go at least expensive while maintaining good quality in terms of supply. In total it costs me less than 160 euros! I am breathing. Finally my finances are breathing. I had a discount on gaskets and a two stirrup repair kit. Banquo!

I am doing a lot more than I need to, but I don’t regret it. Again, this bike is built for safe riding and especially fun learning. I decided not to spend too much anymore, while maintaining the main goal: to spend only. That is, do not overdo it, but do not skimp on what seems necessary to me. And here the replacement proves to me that I have succeeded. I could have saved the plates, which would have cost as little as one hundred euros.

Here and what if I did the same behind? Just to make the brake fluid profitable? And not to lose your hand? 15 € please, thank you! On the other hand, it is easier, faster and a little cheaper: instead of 12 pistons there are only 1 ...

But put it this way, this is what it moves forward, this bike is restarting!