Front, Dual Piston Caliper Identification? - Kawasaki KLR 650 Forum
1987 to 2007 Wrenching & Mods For maintaining, repair or modifications of Generation 1 KLR's. 2007 and earlier.

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post #1 of 11 Old 04-20-2017, 08:07 PM Thread Starter
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Front, Dual Piston Caliper Identification?

Hi All!

Time to change the front brake pads on my bike, but the PO replaced the stock caliper with a dual piston. And now I don't know which pads I should buy. It looks like it might be an SV650 caliper?

What do you all think? Thanks!


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post #2 of 11 Old 04-21-2017, 12:10 AM
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It looks like the caliper isn't mounted to the fork properly.Perhaps the adapter/mount is not made properly. The wear from the pads indicates the caliper is too far out from center and is not on the rotor fully. You may find the pads are not worn all the way across. It also looks like a mounting bolt is sawing a groove in the center portion of the rotor. That is very dangerous. The rotor could break or the caliper could jam causing the front wheel to lock up at any time. I would not ride that bike till the front brakes are repaired properly.
Best Regards....justjeff
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Last edited by justjeff; 04-21-2017 at 12:38 AM.
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post #3 of 11 Old 04-21-2017, 12:37 AM
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Telefonica,
This kind of thing really bothers me. It looks like someone just cobbled together some pieces without having a clue as to what they were doing or the possible consequences if it isn't done correctly.
So what you are going to have to do is replace the rotor because of the damage, get new pads and replace that mounting bracket with a quality, properly designed bracket to mount the SV caliper to the fork for a 320mm diameter rotor. I recommend this one from Eagle Mike who is a big supporter of KLRs.Caliper plate for 320mm rotor, 2008 and later
Before anything though You are going to need to VERIFY that the caliper is DEFINITELY from a SV650. If not you need to get one.Your LIFE IS ON THE LINE. Make sure you do this right.
Best Regards....justjeff
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post #4 of 11 Old 04-21-2017, 12:46 AM
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Thats the cheap ebay kit, I tried it. It bent. It shoudl be avoided. If you have the means buy an $20 ebay SV650 caliper and the adapter plate from eagle mike. Search my youtube channel wandering beast; I have a three part brake upgrade series that shows the issue. I apologize but I havent been on this forum long enough to post URLs.
https://m.youtube.com/user/beast12101

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post #5 of 11 Old 04-21-2017, 02:54 AM Thread Starter
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Quote:
Originally Posted by justjeff View Post
Telefonica,
This kind of thing really bothers me. It looks like someone just cobbled together some pieces without having a clue as to what they were doing or the possible consequences if it isn't done correctly.
So what you are going to have to do is replace the rotor because of the damage, get new pads and replace that mounting bracket with a quality, properly designed bracket to mount the SV caliper to the fork for a 320mm diameter rotor. I recommend this one from Eagle Mike who is a big supporter of KLRs.Caliper plate for 320mm rotor, 2008 and later
Before anything though You are going to need to VERIFY that the caliper is DEFINITELY from a SV650. If not you need to get one.Your LIFE IS ON THE LINE. Make sure you do this right.
Best Regards....justjeff
Wow, I had no idea it was that bad, and I'm impressed you could tell all of that from a few pics!

Just ordered brand new everything, and the bracket from Eagle Mike. Thank you! You may have just saved me from going over the handle bars, can't thank you enough.
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post #6 of 11 Old 04-21-2017, 09:56 AM
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I'm late to the draw but I also ordered that same CZR kit on E-bay once upon a time. After it arrived I quickly determined that it sucked......I had no confidence in the mounting arrangement or hardware and was skeptical of the caliper (which is a chinese knock off copy of a Honda Goldwing caliper if you care). I did use the rotor but it was also inferior and started to loosen (plus I had to shave my rotor mounting bolts to get everything to fit with the SV caliper) so I recently replaced it with the EBC 320mm from Eaglemike.

These days the solution is pretty easy; 320mm rotor, SV caliper adaptor and a russel SS line all from Eaglemike and then a used Suzuki caliper off Ebay. Add a dime mode for brake lever positioning and you're done and now have real brakes using quality components.

Cheers,
Dave
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post #7 of 11 Old 04-21-2017, 10:02 AM
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....so yeah, you need a new caliper. Also I'd bet that the PO used the knockoff Chinese Ninja EX500 master cylinder.....personally, I wouldn't trust that either and would replace it with a stocker.




This is the SV caliper using a bracket I made from a .pdf file before EM started making them. The CZ rotor is still on in this pic which I've since upgraded to the EBC.


Dave
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post #8 of 11 Old 04-21-2017, 10:05 AM
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....google " How I made my brakes work for only $21" for more reading on the subject and the history of the SV caliper mod.


Dave
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post #9 of 11 Old 04-21-2017, 10:53 AM Thread Starter
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Wow, thanks for all the help guys. Looks like I need to replace the entire front brake system just to be safe. Everything on order!
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post #10 of 11 Old 04-21-2017, 11:08 AM
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Quote:
Originally Posted by beast1210 View Post
Thats the cheap ebay kit, I tried it. It bent. It shoudl be avoided. If you have the means buy an $20 ebay SV650 caliper and the adapter plate from eagle mike. Search my youtube channel wandering beast; I have a three part brake upgrade series that shows the issue. I apologize but I havent been on this forum long enough to post URLs.
Good videos; thanks for posting.

Watching them reminded me that I wanted to pack the pin, clip and spare pads in my tool pouch for longer trips. I bought the ebay setup for both KLR's as a set of two calipers so I have extra cups/pins, etc.

Cheers,
Dave
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