Discussion
I've not been fab of the Harrison 6 pot calipers that it came fitted with, the feel at the lever was rubbish, really hard and not much feel, I didn't like braking to a point that was not of my own choosing I e. Late changing traffic lights.
So today I fitted a missing radial master cylinder from Yamaha R1m, it took a while to bleed but eventually we got there.
It's quite a soft lever, but I can now feel when the brakes are starting to bite and brake hard enough to compress the front suspension
The lever travel us grater but I can use two fingers rather than the 4 I was using.
So today I fitted a missing radial master cylinder from Yamaha R1m, it took a while to bleed but eventually we got there.
It's quite a soft lever, but I can now feel when the brakes are starting to bite and brake hard enough to compress the front suspension
The lever travel us grater but I can use two fingers rather than the 4 I was using.
Update more problems....my fault as the car broke when we had the two really cold/snowy weeks and the locals gritted the roads.
Rear caliper, always been a bit sticky, then it was just stuck, took it off to pump the pistons out but one wouldn't budge, so I took it apart but my piston pliers wouldn't work as it was very stuck
Off to YouTube, box spanner and a extension bar stuck in long and hard enough to twist and pull the pistons out, loads of corrosion behind the seals.
Cleaned up everything,red rubber grease on and behind the seals and rebuilt with stainless pins
Bloody thing wouldn't bleed, off to eBay for a vacuum brake bleeding kit, worked well all sorted
Next the clutch master cylinder....
Rear caliper, always been a bit sticky, then it was just stuck, took it off to pump the pistons out but one wouldn't budge, so I took it apart but my piston pliers wouldn't work as it was very stuck
Off to YouTube, box spanner and a extension bar stuck in long and hard enough to twist and pull the pistons out, loads of corrosion behind the seals.
Cleaned up everything,red rubber grease on and behind the seals and rebuilt with stainless pins
Bloody thing wouldn't bleed, off to eBay for a vacuum brake bleeding kit, worked well all sorted
Next the clutch master cylinder....
The clutch started getting a bit odd on the way to work, the clutch was biting right near the bar, literally move it a few millimetres and it was off, a little disconcerting, then after work no clutch lift at all,the fluid in the master cylinder had disappeared, so on the way home it was stop at lights dead engine, into gear and start with the starter motor engaged and kind of make a smooth a start as possible looking as cool as anything whilst kangarooing the first 20 or so feet until the engine burst into life
I ordered a kit and removed, cleaned and rebuilt the slave cylinder
So far I'm getting no pressure and still lots of air, I'm thinking that their is air getting past the threads of the bleed nipple,as it's sealing ok when I do it up, I'm going to remove the slave and try and bleed it on the bench as it's awkward to see anything when it's still bolted to the bike
I ordered a kit and removed, cleaned and rebuilt the slave cylinder
So far I'm getting no pressure and still lots of air, I'm thinking that their is air getting past the threads of the bleed nipple,as it's sealing ok when I do it up, I'm going to remove the slave and try and bleed it on the bench as it's awkward to see anything when it's still bolted to the bike
The problem wa....a split hose, it's almost car type, rubber at the handlebars and then into metal, it split around the join.
Replaced with stainless, but the bugger still wouldn't work, so master cylinder rebuild kit ordered.
The master cylinder was quite dirty when I took it to bits, cleaned it up and new seals etc, I'd bought a £12 eBay vacuum brake bleeder which works really well.
I bled the system but it didn't feel right, the lever started too near the bars, the oe spring wa a little longer, so I took everything apart again and refitted the oe spring, bled it up and.....it seems ok but I've discovered that it's only running on pots 2+3 as it's still really bad at starting.
So I started it and touched the downpipe 2+3 were hot and 1+4 were cold.
I've ordered new pilot jets and some zx636r stick coils, I've got Tuesday off so carbs off and new pilots fitted then make a loom and fit the stick coils.
If it's still crap I'm selling it
Replaced with stainless, but the bugger still wouldn't work, so master cylinder rebuild kit ordered.
The master cylinder was quite dirty when I took it to bits, cleaned it up and new seals etc, I'd bought a £12 eBay vacuum brake bleeder which works really well.
I bled the system but it didn't feel right, the lever started too near the bars, the oe spring wa a little longer, so I took everything apart again and refitted the oe spring, bled it up and.....it seems ok but I've discovered that it's only running on pots 2+3 as it's still really bad at starting.
So I started it and touched the downpipe 2+3 were hot and 1+4 were cold.
I've ordered new pilot jets and some zx636r stick coils, I've got Tuesday off so carbs off and new pilots fitted then make a loom and fit the stick coils.
If it's still crap I'm selling it
An update update if you see what I mean....
I stripped the cabs again, the new pilot jets had arrived, I took everything I could out or off and sprayed every orifice and the really small ones under the carb butterflys got stuck through with a single strand of wire ( the picture hanging stuff)
I reset the floats to around 13-14mm.
I set up a aux tank which was a funnel stuck in place of the tank and petrol in a jam jar(strawberry)
As it's got a pump and empty float bowls, the fuel disappeared with each one second press......then it started and it was running on all 4 cylinders, I was shocked, it probably was the brand new pilot jets, but there was a load of crap in the system when I first got it so probably a combo of both
So today I thought I'd go for a ride, but first check stuff, the clutch master and slave were rebuilt by myself........
In gear on the centre stand and the rear wheel spins round all ok, pull the clutch in and stop the rear wheel with the rear brake,all ok, then off of the stand to go up the slope to the road,no drive bugger, back onto the stand and the rear wheel stops in gear with the clutch lever released, I loosend the clutch slave and the clutch bit as it should
Both bits were stripped again and the metal parts put into the ultrasonic cleaner and rebuilt, tomorrow I should be able to bleed them and try again
I stripped the cabs again, the new pilot jets had arrived, I took everything I could out or off and sprayed every orifice and the really small ones under the carb butterflys got stuck through with a single strand of wire ( the picture hanging stuff)
I reset the floats to around 13-14mm.
I set up a aux tank which was a funnel stuck in place of the tank and petrol in a jam jar(strawberry)
As it's got a pump and empty float bowls, the fuel disappeared with each one second press......then it started and it was running on all 4 cylinders, I was shocked, it probably was the brand new pilot jets, but there was a load of crap in the system when I first got it so probably a combo of both
So today I thought I'd go for a ride, but first check stuff, the clutch master and slave were rebuilt by myself........
In gear on the centre stand and the rear wheel spins round all ok, pull the clutch in and stop the rear wheel with the rear brake,all ok, then off of the stand to go up the slope to the road,no drive bugger, back onto the stand and the rear wheel stops in gear with the clutch lever released, I loosend the clutch slave and the clutch bit as it should
Both bits were stripped again and the metal parts put into the ultrasonic cleaner and rebuilt, tomorrow I should be able to bleed them and try again
Update
I've used it for a few weeks to commute, it's very light on its feet when moving but still a heavy old pig when pushing it around.
The pilot jets were (now it's obvious) the problem with starting/running since I got it in September last year.
I'm still nowhere near using all of the performance,I can Go to work at 3k and when I get above 6k shortly after I'm backing off.
So to this week Monday it was supposed to go below freezing and as I was finishing at 0200 I took the car, I was in London waiting for my train to head back and the wife messages me,(2215) she heard banging and opened the bathroom window to be greeted by 6-8 people in masks having a go at the bike, they ran off.
I rang the cops who went round, mainly wanted a check on the area as the family were home.
The damage??? One smashed lock, it held up and I removed it with the key, they had smashed the outer casing but not the main lock, one disc is damaged beyond use and they have bashed the front wheel.
I got home about 0245 and put another lock on and went to bed.
Next day I moved it removed the front wheel,put it on stands and covered it up, no garage option
So I'm not going via the insurance £350 excess and they would probably scrap it, so I'm going to get a matching pair of discs(zzr1200) £50-75 and I'm thinking of later zzr1200 wheels as the std ones are really heavy, I've been offered a set for £125.
I've got a security camera WiFi thing on the way and the cover will be used at all times from now
I've used it for a few weeks to commute, it's very light on its feet when moving but still a heavy old pig when pushing it around.
The pilot jets were (now it's obvious) the problem with starting/running since I got it in September last year.
I'm still nowhere near using all of the performance,I can Go to work at 3k and when I get above 6k shortly after I'm backing off.
So to this week Monday it was supposed to go below freezing and as I was finishing at 0200 I took the car, I was in London waiting for my train to head back and the wife messages me,(2215) she heard banging and opened the bathroom window to be greeted by 6-8 people in masks having a go at the bike, they ran off.
I rang the cops who went round, mainly wanted a check on the area as the family were home.
The damage??? One smashed lock, it held up and I removed it with the key, they had smashed the outer casing but not the main lock, one disc is damaged beyond use and they have bashed the front wheel.
I got home about 0245 and put another lock on and went to bed.
Next day I moved it removed the front wheel,put it on stands and covered it up, no garage option
So I'm not going via the insurance £350 excess and they would probably scrap it, so I'm going to get a matching pair of discs(zzr1200) £50-75 and I'm thinking of later zzr1200 wheels as the std ones are really heavy, I've been offered a set for £125.
I've got a security camera WiFi thing on the way and the cover will be used at all times from now
light update...
I managed to get a stainless Remus for £85 delivered, I was dreading getting the old one off as it's quite manky underneath.
It was fairly simple, the header nuts and studs looked pretty new, the main issue was the mounting bracket under the sump, lying on my back outside on paving slabs wasn't fun.
Fitting the Remus was ok, it came to me with the downpipes and mid section fitted together, so into the vice a bit of lube and I couldn't move them, so with the help of my son I attempted to fit it, no way was it going around the filter and the headers going into place.
Back to the vice and using a small screwdriver I loosened the slip joint, added lube and did a push me pull you with my son , we got it apart, loosely fitted and tighten it all up.
It's about 6-7kgs lighter than the std, it seems more than that when you are wrestling the old system off.
I've also wrapped the downpipes till past the radiator, they get very hot and judging by the state of the original rad it will be a zzr1200 upgrade over winter.
It's sooo much quieter, in fact it makes the engine sound like a bag of spanners, going to investigate that.
Also whilst the fairing was off I've fitted a led 'bulb' in place of the h4, update later as a t light currently.
I was going to sell the zrx1200 wheels and get some zx10r ones and make them fit, but I've not tried the rear zrx wheel yet, I'm going to get a sprocket carrier and give that a go first.
Off to work later on it , wish me luck
I managed to get a stainless Remus for £85 delivered, I was dreading getting the old one off as it's quite manky underneath.
It was fairly simple, the header nuts and studs looked pretty new, the main issue was the mounting bracket under the sump, lying on my back outside on paving slabs wasn't fun.
Fitting the Remus was ok, it came to me with the downpipes and mid section fitted together, so into the vice a bit of lube and I couldn't move them, so with the help of my son I attempted to fit it, no way was it going around the filter and the headers going into place.
Back to the vice and using a small screwdriver I loosened the slip joint, added lube and did a push me pull you with my son , we got it apart, loosely fitted and tighten it all up.
It's about 6-7kgs lighter than the std, it seems more than that when you are wrestling the old system off.
I've also wrapped the downpipes till past the radiator, they get very hot and judging by the state of the original rad it will be a zzr1200 upgrade over winter.
It's sooo much quieter, in fact it makes the engine sound like a bag of spanners, going to investigate that.
Also whilst the fairing was off I've fitted a led 'bulb' in place of the h4, update later as a t light currently.
I was going to sell the zrx1200 wheels and get some zx10r ones and make them fit, but I've not tried the rear zrx wheel yet, I'm going to get a sprocket carrier and give that a go first.
Off to work later on it , wish me luck
And the flipping thing broke down on the way home, I got about 10 out of the 12.5 miles home, turned into a unlit road, I was seeing how the new led light would cope , hit a bump and everything cut out instantly, no lights or engine and no street lights either, a bloke in a car stopped, we had a look but everything is hidden or bolted down, I spoke to a local house and dumped it in the driveway.
Going back in the morning with tools.
I'm assuming the main fuse went, not sure why yet
Going back in the morning with tools.
I'm assuming the main fuse went, not sure why yet
It's been a while
Not ridden yet only fitted and bled this morning, currently I'm ironing as I'm so very rock and roll.
It was originally built for a zzr11c model not the D that I have, I've had to fettle it a bit , usual stuff, hacksaw, Dremel, carbon burr and a file.
The bit that was the problem is the bit in-between the two mounting bolts,
I've removed some of the fork bracket and a bit off of the socket for the big bolt that makes it radial.
You may have noticed the exquisite hand made washers masquerading as a spacer, the radial bolt it TI so I'm going to get a shorter one
So far after bleeding the brakes don't drag, nice lever feel and they go on and release well.
Not ridden yet only fitted and bled this morning, currently I'm ironing as I'm so very rock and roll.
It was originally built for a zzr11c model not the D that I have, I've had to fettle it a bit , usual stuff, hacksaw, Dremel, carbon burr and a file.
The bit that was the problem is the bit in-between the two mounting bolts,
I've removed some of the fork bracket and a bit off of the socket for the big bolt that makes it radial.
You may have noticed the exquisite hand made washers masquerading as a spacer, the radial bolt it TI so I'm going to get a shorter one
So far after bleeding the brakes don't drag, nice lever feel and they go on and release well.
Not a lot has happened since the last update.
It was used through most of the winter because someone bought a mk4 golf estate with a short MOT which then failed and needed work.
The radial calipers were the last major change, I didn't like the feel from and the amount of force you had to put through the brake lever.
After a bit of research I found out that the r1m Yamaha radial master cylinder had a 15mm bore, looking online it seems I needed a 17.5mm or a 19mm
I was gifted a cbr100rr master cylinder that is 17.5mm bore.
I fitted it today which was a pain as the Banjo bolt was where the throttle cables wanted to go, so I turned the switchgear around the handlebar a bit, this meant the switchgear wiring was now in the way but much easier to reroute
The feeling is not night and day but most of the time (20 miles so far) I could two finger brake
I'm going to try a 19mm (k5 onwards gsxr) radial and see which I prefer
It was used through most of the winter because someone bought a mk4 golf estate with a short MOT which then failed and needed work.
The radial calipers were the last major change, I didn't like the feel from and the amount of force you had to put through the brake lever.
After a bit of research I found out that the r1m Yamaha radial master cylinder had a 15mm bore, looking online it seems I needed a 17.5mm or a 19mm
I was gifted a cbr100rr master cylinder that is 17.5mm bore.
I fitted it today which was a pain as the Banjo bolt was where the throttle cables wanted to go, so I turned the switchgear around the handlebar a bit, this meant the switchgear wiring was now in the way but much easier to reroute
The feeling is not night and day but most of the time (20 miles so far) I could two finger brake
I'm going to try a 19mm (k5 onwards gsxr) radial and see which I prefer
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