Caliper refurb 1989 FZR600 - recommendations?
Discussion
Very near to completing my resto of my '89 FZR600 after re-acquiring the exact bike 35 years after I sold it.
Everything done now except brakes. I've got braided steel lines, but all the calipers look s
t and the rear caliper is in dire need of a refurb. May as well get all three done and get it ready for the spring. Wasn't going to get them done - but now they let the whole bike down so need doing.
Does anyone have any direct experience of who to use for restoring / refurbing calipers for painting, new seals, nipples - new everything basically - so I can ship them off for the work over the winter months?





Everything done now except brakes. I've got braided steel lines, but all the calipers look s

Does anyone have any direct experience of who to use for restoring / refurbing calipers for painting, new seals, nipples - new everything basically - so I can ship them off for the work over the winter months?
Superbike Surgery
https://www.superbikesurgery.co.uk/
Check him out on Youtube, he posts regular videos, including ones of caliper rebuilds if you wanted to get an idea of his work. He is an excellent mechanic
https://www.superbikesurgery.co.uk/
Check him out on Youtube, he posts regular videos, including ones of caliper rebuilds if you wanted to get an idea of his work. He is an excellent mechanic
Why not do them yourself?
You have obviously got the capability.
The worst part is getting the pistons out, but an air line and some g cramps to wrangle them away works.
I've done quite a few over the years and never found it too taxing.
Get a kit with seals (including the seals for the caliper halves), use red grease and replace any fluffy pistons.
You have obviously got the capability.
The worst part is getting the pistons out, but an air line and some g cramps to wrangle them away works.
I've done quite a few over the years and never found it too taxing.
Get a kit with seals (including the seals for the caliper halves), use red grease and replace any fluffy pistons.
Biker's Nemesis said:
I've had 4 FZR 600's over the years, I had the chance to buy my last one 17 years ago for £800, I regret not buying it.
Anymore photo's of it?
I’ll dig some more out and post them up. This wa my bike in 1989 with 600 miles on it, found the same bike for sale in September 2023 with 43000 miles on it so it’s been around the block!Anymore photo's of it?
Few more pics. Lower fairing needs fitting and the exhaust is blowing for some reason at the moment around the headers, can't quite figure out why, but once that's done and the calipers are back on, should sail through the MOT.
When I had it when I was 17/18, I went to the south of France with it and a then-friend on his BMW. When I last rode it about 18m ago, I drove it 20 miles away and thought it was possibly the most uncomfortable thing I've ever ridden unless you're doing 75+mph when the riding position starts to work
I came across the bike purely by chance aboutn two years ago, and thought it'd be a quick and easy rebuild but once I got into it, realised there were several problems. First and foremost, the engine was completely shot. Couldn't find another decent FZR600 engine that hadn't done a million miles, so a YZF600 Thundercat engine has been put in it's place (noting my comment about keeping it as original possible, this was the only option tbh) and wiring loom - that was done by a specialist near me. Then wheels, frame, other bits powder coated, engine and electrics refitted. Bodywork was smashed, bits of fairing missing, splits in both lower fairing panels - so that went to Dream Machine for a full refurb. I tried fitting the YZF exhaust but it doesn't fit under the fairing so the FZR exhaust is going onto the YZF engine, which is probably why it's blowing, but it seems to fit well visually, so a little more digging around is required. Then that's pretty much it. It's well over budget and I've spent far more than it's worth, but it's so nice to have it back after all this time.
South of France 1990

Fresh off the transporter Sept 2023

Fresh off the transporter Sept 2023

Sept 2024

Post-rebuild Sept 2025

When I had it when I was 17/18, I went to the south of France with it and a then-friend on his BMW. When I last rode it about 18m ago, I drove it 20 miles away and thought it was possibly the most uncomfortable thing I've ever ridden unless you're doing 75+mph when the riding position starts to work

I came across the bike purely by chance aboutn two years ago, and thought it'd be a quick and easy rebuild but once I got into it, realised there were several problems. First and foremost, the engine was completely shot. Couldn't find another decent FZR600 engine that hadn't done a million miles, so a YZF600 Thundercat engine has been put in it's place (noting my comment about keeping it as original possible, this was the only option tbh) and wiring loom - that was done by a specialist near me. Then wheels, frame, other bits powder coated, engine and electrics refitted. Bodywork was smashed, bits of fairing missing, splits in both lower fairing panels - so that went to Dream Machine for a full refurb. I tried fitting the YZF exhaust but it doesn't fit under the fairing so the FZR exhaust is going onto the YZF engine, which is probably why it's blowing, but it seems to fit well visually, so a little more digging around is required. Then that's pretty much it. It's well over budget and I've spent far more than it's worth, but it's so nice to have it back after all this time.
South of France 1990
Fresh off the transporter Sept 2023
Fresh off the transporter Sept 2023
Sept 2024
Post-rebuild Sept 2025
Edited by SuffolkDefender on Saturday 4th October 08:04
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