Hello all! I am pretty new to the forum and have found a gold mine! I am only 19 and have already been hooked by old two strokes! I am in the process of getting my '77 RD400 on the road for the first time in 35+ years and would like to do a brake upgrade. I have seen many great builds of the folks on the forum and would like to give it a shot. So far I have been able to acquire a 2001 r6 caliper and a fzr600 rotor, and am working on the caliper adapter by hand. Pretty much all I need is a rotor spacer. I don't have the precision equipment needed to make one and would like to know if anybody could help me out.
Thanks everybody!
Nick
http://www.2strokeworld.net/forum/index.php?topic=184.0
Mark mentions a 12mm spacer at the beginning of this post. I'm about to embark on this journey myself. This one is in the Tech Library section.
I'm about five days from having my mill back on line. I can machine you one once I'm back working. I forget what I charge to do that, but as I recall it's not too expensive as it's a fairly easy part to make.
TBH I THINK I NEED TO UPDATE THAT TO 13MM. SORRY CAPS, DOING SPEC SHEETS AT WORK. I'LL MEASURE MINE, THE PROJECT IS HERE AT WORK IN THE WAREHOUSE.
Thanks guys! Much appreciated!
yup. 13mm (1/2")
I used 1/2 and I barely had to file the caliper for clearance.
I've got to say now that I've actually made the rotor spacer, pretty much by eye and trial and error, I should have just bought one..! I used close to $150 in materials and tools when one could be bought for 50 now...
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675 (https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675)
Quote from: Frank B on November 03, 2019, 11:28:47 PM
I used 1/2 and I barely had to file the caliper for clearance.
I've got to say now that I've actually made the rotor spacer, pretty much by eye and trial and error, I should have just bought one..! I used close to $150 in materials and tools when one could be bought for 50 now...
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675 (https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F152807931675)
Cool! It's nice to see I have some options! What caliper/rotor did you use? I'm not sure what size thickness spacer to use...
Nick
I used fzr600 rotor and an fz8 caliper, Zuma 50 11mm master cylinder . Just because that's what was a good price when I did it. There are a lot of models that use the same rotors and calipers and different colors too. You'll need A new or different brake line, cheap on eBay as well. Longer bolts to hold the rotor on, and chase the threads in the wheel with a tap all the way in.
There still was a little filing and massaging to do but it works great. Don't be put off if it rubs a little and you need to file something to get it to clear..
yeah, frank did good on his for sure. :patriot:
Sweet thanks for the tips. Found a master cylinder that will work, but can't seem to find the right brake line. Any advice? Most seem like the universal type that probably won't work...
Nick
Quote from: 2smokenNick on November 04, 2019, 02:15:09 PM
Sweet thanks for the tips. Found a master cylinder that will work, but can't seem to find the right brake line. Any advice? Most seem like the universal type that probably won't work...
Nick
Russell stainless brake lines come in all sorts of lengths and ends just thread on so you can chose straight or angled as needed
Cheap eBay ones I used, front and rear.
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704 (https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704)
Quote from: m in sc on November 04, 2019, 09:02:32 AM
yeah, frank did good on his for sure. :patriot:
I had great guidance ;D
Quote from: Frank B on November 04, 2019, 09:58:27 PM
Cheap eBay ones I used, front and rear.
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704 (https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704)
Thank you for the link. I'll give the 31.5 inch ones a try...or maybe go longer? Shorter?
Nick
Quote from: Frank B on November 04, 2019, 10:03:04 PM
Quote from: m in sc on November 04, 2019, 09:02:32 AM
yeah, frank did good on his for sure. :patriot:
I had great guidance ;D
Wow, that's cheap!
I was looking at about $70 to have them made locally.
I'd have to measure it later, but I think that'll work.
hopefully we'll be getting some cnc machines again soon, the shop quit and went dormant when i left back in 09, and im back at that company. we were looking at new ones today actually. stay tuned. :haw:
Quote from: pdxjim on November 04, 2019, 10:08:30 PM
Quote from: Frank B on November 04, 2019, 10:03:04 PM
Quote from: m in sc on November 04, 2019, 09:02:32 AM
yeah, frank did good on his for sure. :patriot:
I had great guidance ;D
Wow, that's cheap!
I was looking at about $70 to have them made locally.
The seller is in California so I'd guess that they're made in and imported from China but they're holding up to some hard riding..
Here's a completed pic of the front brake upgrade on mine,
(https://i.ibb.co/N2WBbh1/CF126-BB6-42-C5-4-D2-B-B046-5-DDD2-A20-D092.jpg)
That looks fantastic! Pretty much exactly what I'm aiming for!
Nick
Mine on the Yellow Screamer
(https://photos.imageevent.com/supertune/motorcyclepics/large/20191021_204715.jpg)
(https://photos.imageevent.com/supertune/motorcyclepics/large/20191021_204734.jpg)
Chuck
RD400 with a rules restricting 2 piston caliper off my F-500 racebike, on Daytona Special 35mm forks.
(https://photos.imageevent.com/supertune/motorcyclepics/large/20191021_202726.jpg)
(https://i.ibb.co/LgtVh9D/F59-A346-C-C26-F-4454-AB8-B-776-C50-A50-CE2.jpg)
I have 27.5" on the front but have lower bars than you and am using the hard line.
Measure with some string and make sure you can turn lock to lock with enough clearance.
Heres mine!
(https://uploads.tapatalk-cdn.com/20191105/1e1782c6adeb5e574e5405ffad89456c.jpg)
Bought the fabbed bits from Garrett, caliper from eBay, a new FZR600 disc from the local motorcycle shop, Galfer braided line and a 13(?)mm "Slimline" master cylinder from Mike'sXS. A fantastic upgrade.
Sent from my iPhone using Tapatalk
Yeah, Garrett's CNC hanger is super nice. :cheerleader:
I was told he no longer makes these parts. Is that true? All of these conversions look killer!
Nick
Got mine from Garrett as well. Still putting my bike together, so I'm a ways out. He was super nice to deal with.
Quote from: Joshua on November 05, 2019, 08:44:50 PM
Got mine from Garrett as well. Still putting my bike together, so I'm a ways out. He was super nice to deal with.
Looks great! How long ago did he make the parts for you?
Nick
I think Garrett has access to a CNC mill again, so you may be in luck 👍
Quote from: pdxjim on November 05, 2019, 09:15:18 PM
I think Garrett has access to a CNC mill again, so you may be in luck 👍
Sweet! I have just about all the parts I need for the conversion except for the rotor spacer. I am trying to make the caliper adapter by hand and it seems to be working out ok. Attached is a picture of my progress so far! (Keep in mind I'm just a novice 19 year old:)
Nick
Here's another picture.
Nick
Keep rocking it! You got it!
yeah, looks good. :patriot:
Thanks guys! Can't wait to get a spacer made and have me some big brakes! There's a cool factor to keeping a bike mostly original, but an even cooler factor of making it your own!
Nick
Looking good :righteous:
Any concern about changing it from original will be forgotten the first time you have a panic stop, and actually stop!
Quote from: 2smokenNick on November 04, 2019, 10:07:41 PM
Quote from: Frank B on November 04, 2019, 09:58:27 PM
Cheap eBay ones I used, front and rear.
https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704 (https://rover.ebay.com/rover/0/0/0?mpre=https%3A%2F%2Fwww.ebay.com%2Fulk%2Fitm%2F273463710704)
Thank you for the link. I'll give the 31.5 inch ones a try...or maybe go longer? Shorter?
Nick
I half assed measured mine and it was 27.5 with stock handlebars. The line had a straight fitting on one end and a slight angle on the other. I put the angled end on the master cylinder.
Thanks guys! It's fun to see a project slowly come together!
Nick
When did the caliper mount move from the front to the back of the fork?
Quote from: rodneya on November 06, 2019, 11:14:07 PM
When did the caliper mount move from the front to the back of the fork?
Not sure what you mean...?
Quote from: rodneya on November 06, 2019, 11:14:07 PM
When did the caliper mount move from the front to the back of the fork?
On US models came with the 400.
Quote from: 2smokenNick on November 05, 2019, 10:03:33 PM
Here's another picture.
Nick
Nick, good effort thus far. If you're doing hand work if recommend making a complete pattern from display cardboard first, then test fit your parts to the cardboard pattern The critical part is the alignment of the two sets of holes and their relationship to each set will determine the rotor path clearing the inside radius of the caliper. Doing the one off part I would bore the holes first then cut your profile. With square edges it's much easier and accurate to drill your holes while hold the part in a vice of some sort. If you're doing it by layout measuring from a straight line is easy, a curved one.. not so much. BTW, are you using the stock RD400 mag wheel, just to be sure? Just trying to give few tips when learning how to make parts from metal.
Cheers, 50gary
Quote from: 50gary on November 07, 2019, 08:44:45 PM
Quote from: 2smokenNick on November 05, 2019, 10:03:33 PM
Here's another picture.
Nick
Nick, good effort thus far. If you're doing hand work if recommend making a complete pattern from display cardboard first, then test fit your parts to the cardboard pattern The critical part is the alignment of the two sets of holes and their relationship to each set will determine the rotor path clearing the inside radius of the caliper. Doing the one off part I would bore the holes first then cut your profile. With square edges it's much easier and accurate to drill your holes while hold the part in a vice of some sort. If you're doing it by layout measuring from a straight line is easy, a curved one.. not so much. BTW, are you using the stock RD400 mag wheel, just to be sure? Just trying to give few tips when learning how to make parts from metal.
Cheers, 50gary
Thanks for the pointers. I know the alignment is the most important part and will be tricky. I got the template off of the forum so that should get me pretty close. Just doing my best. If it doesn't work out, I'll just try again! Yup, keeping the original mag wheels. Hopefully everything works out. Fingers crossed!
What years of the FZR600 for disc?
1990-99 IIRC.
Sent from my iPhone using Tapatalk
Quote from: Seizer on November 08, 2019, 11:42:25 PM
1990-99 IIRC.
Sent from my iPhone using Tapatalk
Thanks, must be the same as the 1000 (89 IIRC) that was what I used on one a couple of years ago thought maybe I remembered wrong.