Fitting FZ1000 Caliper to FZS600

[anutz]

i will look at the pad guides tommorow  night i suspect - then re-assemble and bleed then see if they work ok...

[risticuss]

Correct me if I'm wrong, but doesn't the rear R1 bluespot have the same piston diameters as the fzs600 standard caliper.


I know the pads mount differently, from the bottom leaving the caliper more open to remove water/road crap, but if the pistons are the same it won't affect brake feel at all.

[anutz]

hi, i think the FZS1000 caliper i have put on has larger bore pistons, than the FZS600 stock one - i am not 100% sure, main reason for the change was my rear caliper was in appauling condiiton

Be careful with R1 calipers, i do not think they transfer, they look identical but are different, i know that XJR1300 ones can be used in some cases

I am sure a few on here will comment when they see this so could confirm the pistons are the same or not....

If i get time i will look as they are both in the garage

I suspect you will get different feel and performance as thats one other reason people upgrade, but i literally had no choice and did not see any well conditioned FZs600 ones on ebay

[anutz]

Have a read of this...

http://foc-u.co.uk/index.php?topic=942.0

[unfazed]

The FZS1000 rear caliper pistons are 5mm larger in diameter, 43mm as opposed to the 600 at 38mm.
However the important bit here would be the master cylinder, but the master cylinder on the 600 and the 1000 are exactly the same part number 4BP-2583V-01.
With the 1000 rear caliper on the 600 you will have the same braking setup as on the the 1000 and a caliper less prone to seizing 

For info. This master cylinder was first used on the Japanese only market XJ400 and is used across many bikes in the Yamaha range

[unfazed]

Correct me if I'm wrong, but doesn't the rear R1 bluespot have the same piston diameters as the fzs600 standard caliper.

I know the pads mount differently, from the bottom leaving the caliper more open to remove water/road crap, but if the pistons are the same it won't affect brake feel at all.

You are correct the pistons in the R1 rear Bluespot are also 38mm diameter

[risticuss]

Correct me if I'm wrong, but doesn't the rear R1 bluespot have the same piston diameters as the fzs600 standard caliper.

I know the pads mount differently, from the bottom leaving the caliper more open to remove water/road crap, but if the pistons are the same it won't affect brake feel at all.

You are correct the pistons in the R1 rear Bluespot are also 38mm diameter

I thought so.


As a patternmaker, I was planning to make a new bracket to fit the R1 bluespot onto the fzs600 as I know they don't fit the standard bracket. However, on finding out they were the same piston diameter, and realising you're not really gaining much, other than being less prone to seizing I decided not to bother.

[anutz]

so been at the caliper with a file and a little wet and dry, just took the lips off and its nice and smooth now, old pads seem to fit ok with not a shocking ammount of play, waiting for new ones to arrive...

[sinto]

Nearly look as clean and smooth as your office hands anutz
Well done mate

[unfazed]

Nearly look as clean and smooth as your office hands anutz
Well done mate

 

[anutz]

Just looking at re-aligning the back wheel and then will fix the caliper in place again.....so almost there - need to add some pics of the alignent once i have the wheel sorted...

[anutz]

OK so i may have an issue...

The 2 pistons - should they retarct FULLY and sit flush with the caliper internal surfaces with the bleed nipple loosed off one each chamber...

I suspect they should as all my front ones did - anyone comment..

If so this might be something i need to look into as right no i doubt i would be able to get the pads in and seat the caliper....they both are about 2mm proud when fully retracted...???

will try to pump them out a little them push them back in anyway...

[riedrider]

I suspect they should as all my front ones did - anyone comment..

If the protrusion is equal on both sides it might be normal for this type of caliper.
You can measure the gap between the pistons and the thickness of pads and brake disk and easily calculate if it will fit.

[RMT1983]

Yes they are mate.........................

[RMT1983]

Every home mechanic needs one of these!!!

http://www.ebay.co.uk/itm/BRAKE-DISC-PISTON-PAD-SPREADER-SEPARATOR-BRAKE-CALIPER-CAR-HEAVY-DUTY-44977401-/271521429797?pt=LH_DefaultDomain_3&hash=item3f37f03925

[sinto]

Every home mechanic needs one of these!!!

http://www.ebay.co.uk/itm/BRAKE-DISC-PISTON-PAD-SPREADER-SEPARATOR-BRAKE-CALIPER-CAR-HEAVY-DUTY-44977401-/271521429797?pt=LH_DefaultDomain_3&hash=item3f37f03925

Looks a good bit of kit, but I just use two small bits of wood or plastic, and a screwdriver or such to push them back in.

[riedrider]

I got this one:
https://www.louis.de/en/artikel/rothewald-disc-brake/10003009?filter_article_number=10003009
A little bit more expensive but it works fine and I bought it during a 20% off sales promotion 

[sinto]

Easy to use as well, save my wee knuckles next time me thinks

[riedrider]

I think for bikes the blades are to thick. I always use the thin ones of my tool because in most cases the thicker won´t fit.

[anutz]

OK so one pistons i have sorted out - moves fine now and nice and clean, sits flush etc...

the other will not budge a bit, and one strange observation, if i take the bleed nipple out of the side that WILL seat flush, then pump air in it whistles out the nipple...

Do the same on the other side, NOTHING...

Not messing with it anymore, sending it to powerhouse for a service hopefully they can sort it out

[sinto]

I think for bikes the blades are to thick. I always use the thin ones of my tool because in most cases the thicker won´t fit.

Your probably right, was just showing the idea really

[sinto]

the other will not budge a bit, and one strange observation, if i take the bleed nipple out of the side that WILL seat flush, then pump air in it whistles out the nipple...

Don't understand why your saying 'pump air in'?

Should be brake fluid that's in there

Have you pushed the pistons back far enough to fit over your pads? Then bleed the brakes?

Do the same on the other side, NOTHING...

As above really, I don't understand what your trying to do?

Not messing with it anymore, sending it to powerhouse for a service hopefully they can sort it out

Don't send it yet till you've tried to sort it, will be something simple, take a step back and think it over.

[riedrider]

Do the same on the other side, NOTHING...

Maybe the bleeder hole in the caliper is clogged.

[anutz]

OK so here is what i did ....

Close both bleed nipples...

Use compressed air blown in the brake fluid hole to push out the pistons - piece of material in the disc slot to stop them popping out initially...

Left one moves, right one not a jot of movement...

Left one i can remove and looks fine, and can easily re-seat

Right one just no movement...

I also did a test, open the Left bleed nipple and with the piston ALL the way recessed in air passes to the bleed screw, no such luck on the second piston, no idea what it means....

tried all sorts...

[sinto]

OK so here is what i did ....

Close both bleed nipples...

Use compressed air blown in the brake fluid hole to push out the pistons - piece of material in the disc slot to stop them popping out initially...

Left one moves, right one not a jot of movement...

Left one i can remove and looks fine, and can easily re-seat

Right one just no movement...

I also did a test, open the Left bleed nipple and with the piston ALL the way recessed in air passes to the bleed screw, no such luck on the second piston, no idea what it means....

tried all sorts...

So the pistons are dry at the moment?
If so, before you do the air test, the one that moves ok, put a thicker block in there so it's less to move, better still if it can't move,  smaller bit in piston that won't move at the moment, then try the air again.
I'm thinking that the air is only giving good enough pressure to push out one piston, so needs to be directed to one piston only. Can you pull that piston out by hand or turn it at all? Is it free to move I mean?