1995 zzr1100d

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ssray

Original Poster:

1,133 posts

231 months

Saturday 22nd June
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I managed to get a ride on it today ..

Recently I've got someone else to do the fork,as they would leak after a few months when I did them

Put the original suspension dog bones back on, I put zzr600 ones on as they are longer and give a lower seat height, I also set the rear chain adjuster eccentrics to the upper position as it's a big old bird and I like more than one toe on the floor.

And I did a q/a throttle mod with a cable tie.

I did about 25 miles, the excuse was we had run out of chicken and bacon.

The seat height, I can now only touch down with one foot but all toes, when I first had it it was one toe and that was a stretch, it feels better riding now, a bit more weight on the front end, the forks have 10w in them now as the 15w made it.really harsh.

The throttle feels much better, it's still a lot of throttle movement but It feels more responsive.

The next thing is to repair the fairing lowers, they have cracked and are generally in bad repair, I bought a plastic welder staple thing, mainly because the front mudguard was cracking and even though it's a gpz1100e one as the oe's are not available in good condition at a sensible pric

ssray

Original Poster:

1,133 posts

231 months

Tuesday 1st October
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Brake problem.
New ebc pads fitted (so you don't have to read it again, 19mm radial master cylinder, brembo radial mono lock calipers from a r1200rt )
After fitting the ebc's , one disc would get very hot very quickly and then kinda sized on, the brake lever lost all of its freeplay as well, one caliper was noticeable warmer than the other and the disc was hot , not quite so hot on the other side

Initially the brakes were working very well, with a very good release, either when just pushing around or when riding, no sign of anything rubbing.

I assumed it was the master cylinder, stripped it, no blockage anywhere, into the ultrasound cleaner.

The same happened, so calipers off and two at a time pistons out cleaned, red rubber grease, seals out etc, nothing odd.

Had to remove two pistons ,rebleed the system then get the next two out
Same thing happened .

Thinking of taking the master cylinder off and cleaning again or refitting the r1m radial master cylinder to see what happens.

So far I've tried 15mm,17.5mm and currently a 19mm master cylinder,why? Because I hated the feeling with the std one and Harrison 6 pots

I'm possibly thinking of changing the lines to 'race' type two lines from the master cylinder to the calipers

Any more suggestions??

ssray

Original Poster:

1,133 posts

231 months

Tuesday 1st October
quotequote all
rodericb said:
Symptoms certainly do sound like brakes are binding. Do the pistons in the calipers move reasonably freely - especially back inwards into the caliper? Are the piston seals flat or angled? If they're angled and they're in the wrong way they can just keep pumping the pistons out and out and they'll not retract by themselves when you stop applying pressure through the master cylinder.
Pistons back with thumb pressure, seals seem the correct way round.
They don't seem to be binding as I can feel the suspension bouncy back when I'm riding and release the brakes

ssray

Original Poster:

1,133 posts

231 months

Wednesday
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SteveKTMer said:
Do you think EBC might be the problem ? I stopped using EBC about 25 years ago for various reasons and I wouldn't even ride a motorbike with EBC pads let alone buy any. My local bike shop also stopped fitting them and now fits SBS, which is owned by Brembo.
Maybe or the master cylinder isn't allowing enough fluid back to the reservoir
It's currently in the ultrasound cleaner

ssray

Original Poster:

1,133 posts

231 months

Wednesday
quotequote all
fred bloggs said:
Removed all aluminium corrosion from behind the calliper seals ?
Yes, cleaned out, as they are brembo they are hard anodised even behind the seals