How to: Get a good front brake

Questions regarding the DR800

How to: Get a good front brake

Postby Mr.Z » Mon Nov 27, 2017 3:50 pm

First of all, go to the old lump and put some grease between the front brake lever and the master piston, you will be surprised what that will do.

If you want to keep the old caliper than take it off, take the seals out en put it in boiling water for a half an our or so, let it cool down and clean the seal groves with a Dremel with a copper brush on it. Also clean the holes for the pins on the adapter en put just a bit of silicone grease on the pins.
Put silicon grease in to the grooves and on the [new] seals, polish the pistons and put some silicone grease on them, pour some DOT fluid in the caliper and put in the pistons all the way in [ makes bleeding easy]
Put some copper paste on the pin[s] where the pads go over.

Then if you have some money to spare buy a braided brake hose [ Aliexpress]

Well that makes a difference but if you want a real upgrade get the caliper the 1996 and younger models use.

The old
Image

De new
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From 1996 there's a new front brake, and that one brakes a lot better and fits on the older models [ you will need the adapter from the new brake also]. On the new brake is the name "Tokico" and its also mounted on the bikes on this list. [only a left one will fit! ]

KAWASAKI
ER-5 TWISTER (ER-5/01) (2001 - ) [FRONT]
ER-6F (EX650A) (2006 - ) [FRONT LEFT]
ER-6N (ER650A) (2005 - ) [FRONT LEFT]
KLR 650 (KL650C) (1995 - ) [FRONT]
ZR-7 (ZR750-F1) (1999 - 2003) [FRONT LEFT]
Z 750 (ZR750-J) (2004 - 2006) [FRONT LEFT]
Z 750 (ZR750-M) (2007 - ) [FRONT LEFT]
VN 800 DRIFTER (VN800-C1) (1999 - 2001) [FRONT]
KLV 1000 (KLV1000) (2003 - 2006) [FRONT LEFT]
GPZ 1100 ABS (ZX1100F) (1996 - 1997) [FRONT RIGHT]
VN 15 CL.TOURER (VNT50G) (1998 - 2003) [FRONT LEFT]
VN 1500 CLASSIC (VNT50D) (1998 - 2002) [TOURER /FRONT LEFT]
VN 1500 DRIFTER (VN1500-J1) (1999 - 2001) [FRONT]
SUZUKI
GSF 400 BANDIT (GK75B) (1991 - 1995) [FRONT Mod Yr 1995]
GSF 600 BANDIT (WVA8) (2000 - 2004) [FRONT RIGHT]
GSF 600 S BAND. (WVA8/S) (2000 - 2003) [FRONT RIGHT]
SV 650 (AV) (1999 - 2009) [FRONT RIGHT]
SV 650 /S (WVBY) (2003 - ) [FRONT RIGHT]
GSF 650 /ABS (BANDIT650) (2005 - ) [FRONT RIGHT]
GSF 650 S /ABS (BANDIT650S) (2004 - 2006) [FRONT RIGHT]
GSX 750 (AE) (1996 - 2005) [FRONT RIGHT]
GSX 750 F (AK1113) (1998 - 2002) [FRONT RIGHT]
DR 800 S BIG (SR43B) (1991 - 1999) [FRONT Mod Yr 1996-1999]
VX 800 / U (VS51B/96) (1996 - 1997) [FRONT]
DL 1000 V-STROM (WVBS) (2003 - 2010) [FRONT RIGHT]
M1800 R/R2 INT. (INTRUD1800) (2006 - ) [REAR]
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Re: How to: Get a good front brake

Postby GrahamW » Wed Nov 29, 2017 10:02 am

Does anyone know what brake setup this is, sorry about the bad photo. I know the setup isnt standard and that it nearly threw me over the handle bars once when a car slammed on the anchors in front causing me to break my right mirror.

IMAG0395.jpg


Cheers Graham
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Re: How to: Get a good front brake

Postby Yuza » Wed Nov 29, 2017 10:25 am

Seems standard caliper adapted to KTM/Husaberg WP Extreme fork and Braking disc (270 or maybe 300mm)

I am about to install the same fork but I will use stock 300mm brake disc/caliper from KTM LC4 Adventure
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Re: How to: Get a good front brake

Postby GrahamW » Wed Nov 29, 2017 11:09 am

Yuza wrote:Seems standard caliper adapted to KTM/Husaberg WP Extreme fork and Braking disc (270 or maybe 300mm)

I am about to install the same fork but I will use stock 300mm brake disc/caliper from KTM LC4 Adventure


Ahhh thanks, that makes sense it being the stock caliper with a bracket to allow it to fit the larger rotor. I know the master cylinder is a bigger one so that is probably why the brakes are strong. I was worried about finding the brake pads for it you see but now I know that the oem ones should be ok. :)
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Re: How to: Get a good front brake

Postby Mr.Z » Wed Nov 29, 2017 8:56 pm

It's indeed the original pre 1996 caliper and the disc seems 300mm.

Ow and a KTM LC4 old Adventure disc fits on our front wheel, you have to drill the holes for the bolt up to 8mm [ original 6mm] and use conical bolts.
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Re: How to: Get a good front brake

Postby DHC6 » Mon Feb 19, 2018 5:06 pm

An add-on:

I changed the handbrake pump/main cylinder from the original 14 mm to a 12 mm from a Yam, also a DR 125 has a 1/2" which is plug and play. Makes a lot of difference and is very docile.

R
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How to: Get a good front brake

Postby Yuza » Tue Feb 27, 2018 11:11 am

I have initially fitted ktm 2 piston caliper (stock on 640 adv) with DR’s master cylinder (14mm) but braking was really bad, also because of used pads
Now I have fitted brembo 11mm master cylinder (same used by ktm) with new brembo pads and it is even too powerful!
Consider I run 300mm disc
Do not know yet how progressive it is.
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Re: How to: Get a good front brake

Postby Ponkia » Wed Apr 04, 2018 6:21 am

Hello Yuza,
Thank you for the useful informations about the brake upgrade.
I founded a z750 lefy front caliper with his own adapter, the question is: is the kawasaki adapter valid for the DR 800 forks?
Or do I need to look for his own adapter ( after 1996?)

Thank you in advance for your help

Regards
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Re: How to: Get a good front brake

Postby Mr.Z » Wed Apr 04, 2018 9:46 pm

Hello Ponka,

Hard to say but the chances are that it just fits, you can just try it if you already have it and ask otherwise at what distance the mounting holes are if you have to buy it yet.

Let us now if it fits or not.
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Re: How to: Get a good front brake

Postby Ponkia » Thu Apr 05, 2018 2:06 pm

Caliper on the way from the Bay, as soon as I get it Iwill let you know guys...
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