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Caliper Swapping G2 (1999)

This is a discussion on Caliper Swapping G2 (1999) within the United Kingdom forums, part of the Regions category; Hi guys, seem to be always having problems with my from Tokico Calipers. I push them out, give them a good clean, make sure the ...

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Old 03-05-2009, 08:57 AM   #1
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Caliper Swapping G2 (1999)

Hi guys, seem to be always having problems with my from Tokico Calipers. I push them out, give them a good clean, make sure the levels are good, line up, re-copper grease and braided lines. All's ok for… 100 miles them the brkae lever gets closer to the bar, pistons are not releasing from the caliper at the correct rate as one another. So the question is can i get another model or aftermarket caliper that would suit the zx6r 'G2'? and be more reliable without clean every bloody ride out. Cheers guys
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Old 03-06-2009, 07:27 AM   #2
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hello i rebuilt the calipers on my old ninja not a hard job cant remember where i got the rebuild kit from but its not a hard job mate.
If you decide to go that way give me a shout and ill give you a hand
colin
Ps track bike is being rebuild
new 18000 ml motor, frame going in to be powder coated etc.
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Old 03-07-2009, 01:40 PM   #3
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I've read that if you use a ziptie to keep your lever tight overnight the air trapped in the system will slowly work it's way up the lines, through the open master cylinder and into the resevoir..
Dunno if it's true though. I might try it tonight
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Old 03-08-2009, 10:16 AM   #4
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I didn't try the ziptie thing, I'm a bit reluctant to leave the pads on the disks in this shitty weather.

However, I've done some research and apparently the following list of bikes used the same (or very similar apart from intermals) calipers as the G1/G2:

1999 Kawasaki ZR1100C ZRX
2000 Kawasaki ZR1100C ZRX
2001 Kawasaki ZR1200A ZRX1200R
2002 Kawasaki ZR1200A ZRX1200R
2003 Kawasaki ZR1200A ZRX1200R
2004 Kawasaki ZR1200A ZRX1200R
2005 Kawasaki ZR1200A ZRX1200R
2000 Kawasaki ZX1200A Ninja ZX-12R
2001 Kawasaki ZX1200A Ninja ZX-12R
2002 Kawasaki ZX1200B Ninja ZX-12R
2003 Kawasaki ZX1200B Ninja ZX-12R
1998 Kawasaki ZX600G Ninja ZX-6R
1999 Kawasaki ZX600G Ninja ZX-6R
2000 Kawasaki ZX600J Ninja ZX-6R
2001 Kawasaki ZX600J Ninja ZX-6R
2002 Kawasaki ZX600J Ninja ZX-6R
2005 Kawasaki ZX600J ZZ-R (US model)
2006 Kawasaki ZX600J ZZ-R (US model)
2007 Kawasaki ZX600J ZZ-R (US model)
1996 Kawasaki ZX750P Ninja ZX-7R
1997 Kawasaki ZX750P Ninja ZX-7R
1998 Kawasaki ZX750P Ninja ZX-7R
1999 Kawasaki ZX750P Ninja ZX-7R
2000 Kawasaki ZX750P Ninja ZX-7R
2001 Kawasaki ZX750P Ninja ZX-7R
2002 Kawasaki ZX750P Ninja ZX-7R
2003 Kawasaki ZX750P Ninja ZX-7R
1996 Kawasaki ZX900B Ninja ZX-9R
1997 Kawasaki ZX900B Ninja ZX-9R
1999 Suzuki GSX1300R Hayabusa
2000 Suzuki GSX1300R Hayabusa
2001 Suzuki GSX1300R Hayabusa
2002 Suzuki GSX1300R Hayabusa
2003 Suzuki GSX1300R Hayabusa
2004 Suzuki GSX1300R Hayabusa
2005 Suzuki GSX1300R Hayabusa
2006 Suzuki GSX1300R Hayabusa
2007 Suzuki GSX1300R Hayabusa
2004 Suzuki GSX1300RZ Hayabusa Limited Edition
2005 Suzuki GSX1300RZ Hayabusa Limited Edition
2006 Suzuki GSX1300RZ Hayabusa Limited Edition
2001 Suzuki GSX-R1000
2002 Suzuki GSX-R1000
1993 Suzuki GSX-R1100
1994 Suzuki GSX-R1100
1995 Suzuki GSX-R1100
1996 Suzuki GSX-R1100
1997 Suzuki GSX-R1100
1998 Suzuki GSX-R1100
1996 Suzuki GSX-R750
1997 Suzuki GSX-R750
1998 Suzuki GSX-R750
1999 Suzuki GSX-R750
1998 Suzuki TL1000R
1999 Suzuki TL1000R
2000 Suzuki TL1000R
2001 Suzuki TL1000R
2002 Suzuki TL1000R
2003 Suzuki TL1000R

These have a 90mm bolt spacing, the following calipers share the same spacing and may be valid as a swap:

SUZUKI
Bandit1200, GSX1000R, Hayabusa, GSX750, GSX750 Katana, GSXR750 Slingshot, GSXR1100L, GSXR1100M, GSXR1100N, GSXR1100 Slingshot, GSXR600 (2001 model), GSXR750WR, RF900R, RGV250, RGV250M, TL1000R, TL1000S, Bandit 400 (twin dics model, all years), GSXR750 SRAD (95-99), GSXR600 (96-2000)

TRIUMPH
Daytona 595, 505, Trophy

YAMAHA
FZR750R, OW01

The Suzuki calipers use a different thread pitch for the banjo bolts, m10 x 1.0 instead of m10 x 1.25..

So it looks like there's heaps of options, though I can't personally varify this!

I got all this from a couple of threads on the ZRXOA forums.
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Old 03-09-2009, 03:10 AM   #5
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Cheers guys, Mentok you did some serious work there, much appreciated mate. Alumina, glad the bike is getting sorted and yes i'll be sure to give you a buzz if i need a hand getting the brakes sorted, cheers again guys. p.s. the zip tie thing ive heard before and will give it ago and see what happens. Laterz fellow ninjas.
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Old 03-09-2009, 12:10 PM   #6
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Apparently a lot of people struggle with bleeding the 6 pot calipers and prefer to fit 4 pots, from SRADs/early GSXRs. There's a good thread about this on the PB forum too, can't find the link though.

Good list there Mentok
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Old 03-09-2009, 05:05 PM   #7
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It's tempted me to fit 4 pot Nissins - cheaper pads, more feel, less likely to stick. Apparently.
The whole front end on my ZX feels pretty vague, calipers would be a good start, re-valve after that. As long as I can stop wasting money at the Hein Gericke ebay shop...
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Old 03-16-2009, 06:37 PM   #8
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never had a prob with my front breaks.. they work great just waiting for braided lines to come in they will wicked..

ginger.ninja how often do ya ride the bike?
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Old 03-17-2009, 01:24 AM   #9
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Just re-read this and it sounds more like your master cylinder leaking/poor seal. Had a similar problem on my 1000RX, turns out the previous owener had assembled the master cylinder back to front. Might be worth getting a master cylinder rebuild kit, possibly wemoto stock them, they do a full caliper rebuild kit for £57.
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Old 03-17-2009, 03:12 AM   #10
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Yeap i did the master Cyl repair kit and it was the same, ive looked over the calipers and noticed that the pistons are chewed around the edges so i can assume that previous owners gave them a rough time, the brakes work but not as good as they should, to much movement, the pistons are travelling at different rates, im gonna keep on top of them and just see if i can get 4pot nissins. Cheers for all the replys guys, much needed.
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