Fitting FZ1000 Caliper to FZS600

[anutz]

no luck its stuck.....

[anutz]

going to connect it to the rear line and see if i can use the brake pressure to push it out...

[anutz]

PROGRESS....so refitted the brake line to the rear and the pressue pushed out the stuck piston - the dust seal was warped and chewed up but the piston is in good condition and so have ordered a new seal kit to put in.....

As you hinted Sinto not enough pressure from the footbal pump....

Looking promising again - also have some 0.5mm washer to sort the alignemnt out on the caliper as 1.25mm seems to take it too far back to center and offline again...

shall hopefully eventually post final pics etc 

[sinto]

PROGRESS....so refitted the brake line to the rear and the pressue pushed out the stuck piston - the dust seal was warped and chewed up but the piston is in good condition and so have ordered a new seal kit to put in.....

Better this than sending it away at more cost

As you hinted Sinto not enough pressure from the footbal pump....

Football pump? No wonder it wasn't moving
But guess it would of moved if the seal was ok

Looking promising again - also have some 0.5mm washer to sort the alignemnt out on the caliper as 1.25mm seems to take it too far back to center and offline again...

shall hopefully eventually post final pics etc 

Hurry up man, we've been waiting on more pics
And your missing riding time but then you've still to test it all for its MOT sure it'll sail through with all the foccin work you've done

[anutz]

as a side project i dug out the old caliper - now that i understand more about them i think i can clean it up nicely.....will need re-painting so will post some pics of that as i go....

[anutz]

I wander if anyone can answer my query....all i have left to do it bleed the rear brake....however in thought i would just check the torque on the banjo bolts and it raised a point...

There a "Projections" on the Master Cylinders and Calipers, front and rear, not just specific to this one i am fitting....

In the Service Manuals it highlights the importance of contact being made with these prjections when tightening the banjo bolts...

This is something that is making me have to carefully consider HOW i do this with the bluespot rear i have as the standard hose does not seem to "reach", but i am looking at putting a braided hose  i have on, still i need to know the importance of the "projections"...

Thanks

[riedrider]

The projections should prevent the brake lines from spinning around when you tighten the banjo bolts.
If you can apply the specified torque to the bolts and you can keep the lines in place (maybe with cloth wrapped pliers) everything is fine.

[sinto]

My 2p worth
That sounds like it's only to do with the original pipes and not the braided as it's in the manual, they wouldn't be talking about upgrades I wouldn't imagine.

[riedrider]

If you have good braided lines then the fittings are the same like original and the projections should fit.
Here are braided lines from Melvin on my ex-blue spot calipers. The projection is marked with yellow arrow:



Problems might occur if a caliper is from another bike. Then you can use custom made lines with the right fittings for the caliper.
Examples for fittings on page 4:

[anutz]

The difference is slight between the angle of the Banjo insertion on between the Bluespot Rear i have put on versus the OEM caliper....but it IS enough based on what i have been messing with to stop the projection being adhered to..

Will do some more playing tonight and see if it CAN fit correctly....if not may need to contact HEL and ask them for a longer rear hose and also account for the custom caliper i am fitting....

It is not miles off just too tight to be comfortable, and i am not going to force anything when its related to braking...

[unfazed]

The protrusion as you call them are there to prevent the banjo moving when tightening the banjo bolt. Locate the best position for the banjo with least strain on the hose. Place a piece of metal or a small nut in between the protrusion and the banjo and tighten banjo bolt to the correct torque.

[anutz]

The protrusion as you call them are there to prevent the banjo moving when tightening the banjo bolt. Locate the best position for the banjo with least strain on the hose. Place a piece of metal or a small nut in between the protrusion and the banjo and tighten banjo bolt to the correct torque.

Thanks for that Unfazed, shall take a look later tonight...

[anutz]

OK got it on and updated my origonal post, looks ok and stops the wheel dead so happy for now....watching the bleed nipples again...seem to be doing nothing but watching nipples right now....

[sinto]

OK got it on and updated my origonal post, looks ok and stops the wheel dead so happy for now....watching the bleed nipples again...

Well done

seem to be doing nothing but watching nipples right now....

you could get locked up for that if you get caught