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Old April 27th, 2014, 07:11 PM   #1
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Larger rotor with Brembo 4 pot caliper

So i finally got around to finishing my prototype mounting bracket for this setup.

As it mounted up today it is 100% functional but i will make some very very minute adjustments. Like moving one of the bolt holes 0.02" and decreasing thickness where caliper attaches by about 0.05" and that should give me a little bit more buffer space if it is ever needed.

Doesn't look like much yet but, @Bigballsofpaint has agreed to CNC up a bracket for me. Once i get the first one back and verify that everything is as it should be if he chooses to and can, he could keep making them and it would be very easy for someone to replicate this set up. Buy used 4 pot brembo, make sure it has the further apart bolt spacing i think it is 65mm? whatever, look at pics and get the one that has them further apart. Buy larger Chinese rotor

Here is pic of bracket and a link to the rotor on ebay. Only thing with rotor is contact the seller to try and verify what you get. There are a few sellers on Ebay. For the place i got mine the original ad said you get 2 rotors but i only got 1 and i got some mounting bracket with it that was useless. I contacted them about it and they said i got the right package and they would change their ad

Rotor is Ara Shi 320mm, it looks very solid and well made but have not put it through paces yet

sorry for bad pic, my cell phone camera is cracked and takes terrible pictures and i broke our digital camera yesterday

http://www.ebay.com/itm/151239856301...84.m1497.l2649
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Old April 27th, 2014, 07:36 PM   #2
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good job getting it together and working. I don't know why but I just seem to like the look of the radial mount style better.
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Old April 27th, 2014, 07:39 PM   #3
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Dooooooooooooooood.

Fancy brakes + IRC front tire =
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Old April 27th, 2014, 07:41 PM   #4
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Dooooooooooooooood.

Fancy brakes + IRC front tire =
I didn't notice but this^
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Old April 28th, 2014, 04:20 AM   #5
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Dooooooooooooooood.

Fancy brakes + IRC front tire =
it's on the list
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Old April 28th, 2014, 06:40 AM   #6
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Dooooooooooooooood.

Fancy brakes + IRC front tire =
lol
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Old April 28th, 2014, 06:41 AM   #7
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what has it cost you so far? Looks like a great project
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Old April 28th, 2014, 10:21 AM   #8
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right now total money spent looks like this.

$80 for brembo caliper on ebay
$50ish for new pads, can't remember exactly
$160 for the rotor
$20 for odd ball mounting bolts, banjo bolts & other things needed
$35 after shipping for a plate of 1/2" 8x8 T6 6061 to make my prototype bracket (if cnc guy chooses to make brackets not sure how much he would charge)

$345ish but really the rotor was the only pricey bit which is still pretty cheap and if it needs replaced anyway it would only be a bit more than buying new rotor and pads.

$345 - cost of new rotor and brake pads puts you at $135 on top of normal costs for rotor + pads. Not to bad IMO
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Old April 28th, 2014, 10:51 AM   #9
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You still havent shot me the new dimensions yet
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Old April 28th, 2014, 12:01 PM   #10
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$345 - cost of new rotor and brake pads puts you at $135 on top of normal costs for rotor + pads. Not to bad IMO
Not bad at all
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Old April 28th, 2014, 12:40 PM   #11
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You still havent shot me the new dimensions yet
you should have them in a few minutes, been double checking everything, then triple checking and I had to move one of the holes just a hair and it took me half a day to figure out the trig to accomplish it
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Old April 29th, 2014, 04:55 AM   #12
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it took me half a day to figure out the trig to accomplish it
Wait, really?
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Old April 29th, 2014, 04:59 AM   #13
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well I don't remember any formulas as I never use that stuff in my line of work or when the particular laws can be used and I had to many variables for what I needed to figure out. So I had to figure out like 6 different things before I could get to the angles and sides I wanted to figure out plus i was only messing with it on my down time... but it did take me a while lol

It was a mess
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Old April 29th, 2014, 05:03 AM   #14
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looks like you're getting there. good job.

I like radial brakes too.
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Old April 29th, 2014, 05:43 AM   #15
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Oh... Just use wikipedia when you have questions on math/analysis type stuff. All the stuff I've learned so far in school is, in some form, on wikipedia. It's great review.
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Old April 29th, 2014, 05:47 AM   #16
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i don't really have a preference as far as mounting type
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Old April 29th, 2014, 06:05 AM   #17
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If I bought a new sport bike I would want radial brakes. The 250 does fine with what it has....especially now that I have a full floating setup.
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Old April 29th, 2014, 06:24 AM   #18
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I guess its not as much the fact that its radial mounted as that fact that I like the beefier boxier look of the radial style caliper itself.
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Old April 30th, 2014, 08:40 AM   #19
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Some computer drawings of bracket @Bigballsofpaint sent me

Just hope all my measurements were perfect Not to much wiggle room here
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Old April 30th, 2014, 08:58 AM   #20
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You can make a killing if its a better price then this
http://www.ebay.com/itm/KAWASAKI-NIN...-/271218973225
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Old April 30th, 2014, 09:14 AM   #21
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Let me see what the machine time is before i come up with any of that. I let Joe know ill be ordering the material tomorrow, hopefully i dont scrap much since im only ordering enough for 3.

Edit: It will most certainly be less than that since im not trying to make a business out of this, i doubt my job would appreciate that. Just trying to do a few cool things here and there to help people out if i can.
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Old April 30th, 2014, 09:19 AM   #22
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Let me see what the machine time is before i come up with any of that. I let Joe know ill be ordering the material tomorrow, hopefully i dont scrap much since im only ordering enough for 3.

Edit: It will most certainly be less than that since im not trying to make a business out of this, i doubt my job would appreciate that. Just trying to do a few cool things here and there to help people out if i can.
You guys ever think about one for the pregen 250?
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Old April 30th, 2014, 09:23 AM   #23
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You guys ever think about one for the pregen 250?
If you go back to my original post im not here to do the thinking. Give me some measurements and ill see what i can come up with to help some fellow members out.

Another member wanted clip ons for his pregen - but i didnt like the dimensions he gave me and what he wanted. I still drew up a model that he liked, but i need to go get real measurements off my friends pre gen so i havent touched it in a while.

Joe gave me some pretty solid numbers since he has made a prototype, if one were to do the same with a pregren, i wouldnt mind doing one for that as well.
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Old April 30th, 2014, 09:39 AM   #24
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If you go back to my original post im not here to do the thinking. Give me some measurements and ill see what i can come up with to help some fellow members out.

Another member wanted clip ons for his pregen - but i didnt like the dimensions he gave me and what he wanted. I still drew up a model that he liked, but i need to go get real measurements off my friends pre gen so i havent touched it in a while.

Joe gave me some pretty solid numbers since he has made a prototype, if one were to do the same with a pregren, i wouldnt mind doing one for that as well.
Well thanks for helping your fellow ninja owners out. Any one want to take a crack at the numbers I have no idea the place to start.
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Old April 30th, 2014, 09:44 AM   #25
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You can make a killing if its a better price then this
http://www.ebay.com/itm/KAWASAKI-NIN...-/271218973225
yeah, looking at prices like this is why I decided to make my own, then figured i might as well try and make it look decent as well and that is were Jay comes in.

That bracket is also for the 40mm spacing caliper and I think a stock sized rotor. The caliper I have is 65mm...ish and the rotor is larger I think place I bought it from says 320mm but I should measure to confirm.

The rotor I bought actually came with some adapter bracket but it was clearly not designed for rotor it came with or designed very poorly. The hole spacing was right for the brembo 65mm caliper but the angles/distance form center rotor was all screwy and would have provided little to no bite.

I didn't even know the rotor I bought was supposed to come with the bracket? I was surprised when I found it and excited that it might work.... clearly it did not.

I do like how that ebay bracket is designed. I guess that is an option I didn't consider and would be more plug and play than my design but not by much. Would look a little bit cleaner as well as nothing is bolting on top of fork caliper mount, it would be under just like the OEM.
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Old April 30th, 2014, 09:51 AM   #26
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Well thanks for helping your fellow ninja owners out. Any one want to take a crack at the numbers I have no idea the place to start.
I prefer to work with the pieces as sometimes it might highlight a problem you originally didn't think of. Draw back is you may not consider other options, like mentioned in previous post. I would never considered that option working with what I had as it was not possible to make a prototype like that.

get some parts, caliper & rotor if going larger, get the materials to make a bracket. I used a piece of T6 I had laying around and make some prototype quick with some rough measurements see how bad or good it is, then make some more thoughtout changes to the 1st gen prototype and you should be able to get a final one by the 3rd gen. If you have a little bit of time to devote and decent tools it could be done pretty quickly. Drill press, band saw, bench grinder are key. I had none of thee above Cordless drill, hacksaw, a round file, and a flat file and lots of elbow grease
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Old May 1st, 2014, 12:14 AM   #27
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I guess its not as much the fact that its radial mounted as that fact that I like the beefier boxier look of the radial style caliper itself.
Most here in Asia are running radial style mounts with the 320mm rotor
I think like your pic & this one shows the radial mount does seem to orient the caliper well
on the rotor for max footprint with good leverage.

RSV racing here is making the brackets
Like this

I am also running the 320mm rotor but have not upgraded caliper yet
just HH pads & SS lines
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Old May 1st, 2014, 05:53 AM   #28
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I wouldn't mind a radial caliper especially if I could find a plug and play bracket but the brembo radial calipers are still a bit pricey for a budget build. I got the caliper I have for like $70-$80
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Old May 1st, 2014, 06:28 AM   #29
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I have a tokiko radial caliper on the way from a 05-06 gixxer1000 and a radial master cylinder 16x18... Will be installing it next month once I actually get it...
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Old May 1st, 2014, 06:41 AM   #30
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Man that looks great, keep us posted on updates. Very cool.
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Old May 1st, 2014, 08:50 AM   #31
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Most here in Asia are running radial style mounts with the 320mm rotor
I think like your pic & this one shows the radial mount does seem to orient the caliper well
on the rotor for max footprint with good leverage.

RSV racing here is making the brackets
Like this

I am also running the 320mm rotor but have not upgraded caliper yet
just HH pads & SS lines
that is a nice looking setup. I just hate to imagine the cost.
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Old May 1st, 2014, 09:22 AM   #32
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^ this

I have found some brembo radial calipers as cheap as $200 a pair used but that was the lowest by far and more commonly $300/pair. It is hard to find them individual but you could always try and sell the left over one to make some cash back.

Figure you would get charged at least $100 for the mounting bracket, maybe more, add in some odds and ends and it would be around $450 just for the hardware not including rotor, maybe you manage to sell the left caliper for $100 and net $80 you are still at $370 ish Not terrible I guess but lots of assumptions.
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Old May 1st, 2014, 09:33 AM   #33
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^ this

I have found some brembo radial calipers as cheap as $200 a pair used but that was the lowest by far and more commonly $300/pair. It is hard to find them individual but you could always try and sell the left over one to make some cash back.

Figure you would get charged at least $100 for the mounting bracket, maybe more, add in some odds and ends and it would be around $450 just for the hardware not including rotor, maybe you manage to sell the left caliper for $100 and net $80 you are still at $370 ish Not terrible I guess but lots of assumptions.
For that price is it worth it for the extra braking power on a 250cc? I thought this was a cool mod and looked up the brakes. Couldn't find any new for less than $700. Maybe I'm looking in the wrong places.
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Old May 1st, 2014, 09:38 AM   #34
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Hey Joe, would you want me to mock up a design that uses the M8 holes threaded under the fork instead of using bolts like you are? All i have to do is measure how this the piece is on the fork. Since your design goes on the top, the other goes along the bottom, i should be able to just drop those 2 holes down to sit under the fork. Im pretty sure we have some M8 taps around.
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Old May 1st, 2014, 10:17 AM   #35
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Hey Joe, would you want me to mock up a design that uses the M8 holes threaded under the fork instead of using bolts like you are? All i have to do is measure how this the piece is on the fork. Since your design goes on the top, the other goes along the bottom, i should be able to just drop those 2 holes down to sit under the fork. Im pretty sure we have some M8 taps around.
If it's not to much trouble. Trying to think of how things will be affected.

If you treat the Caliper side with the thicker section as a stationary Zero point, you could probably just measure the thickness of the OEM caliper mount where holes are that is fixed to the right fork and then subtract that + the thickness of the bracket and drop it that far and that would get you to the right spot while maintaining the correct position of the caliper in the Z plane.

When you do it this way, you would also be able to lose the thicker section on the caliper holes as it would not be needed anymore and just make that whole level of the bracket 1/4" from the previous lower point where bracket actual met caliper. It might change some of the clearances with the pots on the caliper but I think we gave ourselves enough room there and should be fine.

Only other thing that would need to be addressed is that the new section that is going to mount to the fork mount on the inside will have to be 0.20" thick, 0.25" I think is just a hair to thick and might contact the buttons of the larger rotor.

Let me know if you are following me, I can give more info in a PM and even do a quick sketch since the hole positions will not change in relation to each other in
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Old May 1st, 2014, 10:19 AM   #36
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For that price is it worth it for the extra braking power on a 250cc? I thought this was a cool mod and looked up the brakes. Couldn't find any new for less than $700. Maybe I'm looking in the wrong places.
Ebay my friend, look for used. It is easiest if you know an old bike that had the brake caliper you are looking for.


For the caliper like I have, ebay search ducati 748 brake caliper. You can find used refurbished for like $300 I think for a pair, or just get used non refurbished for $140/pair

For the radials brembo's ebay search GSXR brembo caliper and it should bring up some used radial brembo cal's for more recent model GSXR's

You won't find anything cheap new.
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Old May 1st, 2014, 10:29 AM   #37
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If it's not to much trouble. Trying to think of how things will be affected.

If you treat the Caliper side with the thicker section as a stationary Zero point, you could probably just measure the thickness of the OEM caliper mount where holes are that is fixed to the right fork and then subtract that + the thickness of the bracket and drop it that far and that would get you to the right spot while maintaining the correct position of the caliper in the Z plane.

When you do it this way, you would also be able to lose the thicker section on the caliper holes as it would not be needed anymore and just make that whole level of the bracket 1/4" from the previous lower point where bracket actual met caliper. It might change some of the clearances with the pots on the caliper but I think we gave ourselves enough room there and should be fine.

Only other thing that would need to be addressed is that the new section that is going to mount to the fork mount on the inside will have to be 0.20" thick, 0.25" I think is just a hair to thick and might contact the buttons of the larger rotor.

Let me know if you are following me, I can give more info in a PM and even do a quick sketch since the hole positions will not change in relation to each other in
Since the bolt holes wont change that is what i was going to go off. Ill take a look at my bike this weekend and see if i can figure anything out. Material wont be in until next week, so ill still 2 weeks or so away. Ill still make your original design though as well, so no worries.
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Old May 1st, 2014, 10:37 AM   #38
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Originally Posted by Bigballsofpaint View Post
Since the bolt holes wont change that is what i was going to go off. Ill take a look at my bike this weekend and see if i can figure anything out. Material wont be in until next week, so ill still 2 weeks or so away. Ill still make your original design though as well, so no worries.
I got ya, perhaps I misunderstood what you are talking about. But do you think you could do one up like I described earlier 2 posts ago, it would be similar to this ebay design. The side that connects up with the fork mount would be on the inside near the rotor. The side that connects up with the caliper would be on top/ outside. This would solve the thread issues on the caliper side and keep everything very plug and play on the fork side.

If you follow what I wrote in that last post about making alterations it would be pretty easy I think.

I could get some measurements with in a few days for everything.

here is link to ebay bracket. It would work same way but just be different size and hole spacing different. I think this would be ideal, I just didn't think of it until I saw this adapter. I would never be able to make a prototype like this with the tools I have so I never considered it an option

http://www.ebay.com/itm/KAWASAKI-NIN...235105&vxp=mtr
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Old May 1st, 2014, 12:43 PM   #39
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Ebay my friend, look for used. It is easiest if you know an old bike that had the brake caliper you are looking for.


For the caliper like I have, ebay search ducati 748 brake caliper. You can find used refurbished for like $300 I think for a pair, or just get used non refurbished for $140/pair

For the radials brembo's ebay search GSXR brembo caliper and it should bring up some used radial brembo cal's for more recent model GSXR's

You won't find anything cheap new.
When looking the off the shelf brackets from SSR that use a 40mm spacing would be for "gold line brembos" from ducati. In like 98 or 99 I think ducati started switching to the 65mm spacing and a 4 pad caliper instead of the 2 pad 40mm unit on the higher end models
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Old May 1st, 2014, 12:56 PM   #40
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^ dunno

think my caliper is off a 01 748. It has 65mm spacing between bolts and has 2 brake pads, just one on each side? but it did have dual rotors/calipers on that bike?
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