Brake Upgrade - 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 26 Old 01-08-2018, 02:16 PM Thread Starter
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Brake Upgrade

So, I'm looking to do the Eagle Mike / SV caliper / 320mm oversize upgrade. Has anyone done this and what is your opinion on this one? The KLR's brakes seem loosy-goosy to me, compared to my sporter with dual fronts. Its an expensive upgrade, about $400 when all is said and done, so I want to be reassured I am spending good money after good and using sound logic. Any drawbacks to this mod? Thanks.
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post #2 of 26 Old 01-08-2018, 02:55 PM
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Oversize (320 mm diameter) brake disk and stainless-steel-wrapped front brake line comprise a worthwhile upgrade, especially on Generation 1s.

Don't know where the, "$ 400" comes from; Tusk oversize brake disk and caliper bracket go for about $ 150, if I'm not mistaken. Riding partner (85,000 miles on his '08) has that setup with CL (I think, French pads) and likes it a lot.

Tusk oversize disk and caliper bracket on Generation 1:



Link to GENERATION 1 (I THINK; CHECK WITH ROCKY MOUNTAIN TO BE SURE) OVERSIZE BRAKE ROTOR AND CALIPER BRACKET KIT:

https://www.rockymountainatvmc.com/p...otor-Kit-Front
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Last edited by Damocles; 01-08-2018 at 03:22 PM.
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post #3 of 26 Old 01-08-2018, 07:07 PM Thread Starter
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OK, so not $400, but $300 and change...

Eagle mike caliper kit- $50
EBC Rotor- $220
SV Caliper- $35
Caliper rebuild kit $15
Pads- $10

I watched Wander Beasts review of the Eagle mike bracket, so I'm sort of sold on it (bracket seems bulletproof). I like the idea of two-piston caliper, so im sold on the SV path. If you know of an alternative I'd like to hear it. Now the rotor is where there is a difference in price. I wasn't aware of the tusk, and that one seems to be $70 cheaper (woot!). Is it good quality? Durable?

It looks like I can do the whole mod with ... $260. That seems fair for new front end braking. Are there mods for the rear brake? It seems ok, but I'm rather new to the KLR. I will say it was 'underwhelming' while I stopped for a car in front of me.
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post #4 of 26 Old 01-08-2018, 11:45 PM
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You do not price stainless-wrapped front brake line.

Nor do you cost your replacement master cylinder, if you insist on going for a dual-piston caliper. You will not enjoy the advantage of a dual-piston caliper without a corresponding master cylinder.

As to Tusk quality; I can't say--as mentioned, my riding partner only has 85,000 miles on his '08; no idea how durable the Tusk kit might be. My partner says the Tusk kit is superior to both EBC and Galfer in wear and performance.

He has CL brake pads; they cost more than the $ 10 you budget, but . . . they do not wear the rotor excessively, as do some pads (like the OEM ones).

All this said, by all means upgrade your brakes in accordance with your own preferences and budget!

Here's a Galfer oversize brake rotor, caliper bracket, and steel-wrapped front brake line on a Generation 1:



(MaY be an EBC rotor, ain't sure.)

With decent pads, I find the arrangement adequate for my riding environment and style; YMMV!

Last edited by Damocles; 01-09-2018 at 10:02 AM.
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post #5 of 26 Old 01-09-2018, 11:02 AM
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Quote:
Originally Posted by Damocles View Post
Nor do you cost your replacement master cylinder, if you insist on going for a dual-piston caliper. You will not enjoy the advantage of a dual-piston caliper without a corresponding master cylinder.
I disagree; the dual piston caliper (SV) upgrade is a VAST improvement over the stock Gen1 caliper and you do NOT need to replace the master; it works great with the SV caliper.

The combination of the SV caliper, 320mm rotor and ss line transforms the Gen1 front brake from dangerous to downright decent and is well worth the time and expense.

To avoid problems, I strongly suggest buying the SV adaptor AND the EBC 320mm rotor (there is more than one part number) directly from Eaglemike. Might as well get the SS line from him as well.

Dave
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post #6 of 26 Old 01-09-2018, 11:04 AM
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post #7 of 26 Old 01-09-2018, 05:30 PM Thread Starter
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Thanks.

I already have ss wrapped lines. I've made some decisions. I purchased the tusk oversize front and pads, and with a tiny bit of money I saved I ordered the rear disk as well. My rear disk was out of spec and the pads were flat. I'm going to order the SV kit and move forward. I value everyone's help with this. I think this set up will make it about as good a stopper as I'm gonna get, which should be safe. I'm sure the EBC is a great rotor, but I expect the Tusk is going to stop the bike as well. Thanks for the help.
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post #8 of 26 Old 01-09-2018, 07:09 PM
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Quote:
Originally Posted by DPelletier View Post
I disagree; the dual piston caliper (SV) upgrade is a VAST improvement over the stock Gen1 caliper and you do NOT need to replace the master; it works great with the SV caliper.
You may not "need" to replace the master cylinder when adding a dual-cylinder caliper but . . . expecting identical performance from master cylinders of different designs and operational capabilities contradicts the laws of hydraulics as I understand them. The old master cylinder may function with a dual-cylinder caliper, but . . . optimally? I doubt it.

Kawasaki installed re-designed master cylinders to match Generation 2 dual-piston front calipers; did not "re-purpose" Generation 1 master cylinders for the purpose.

If, however, one master cylinder optimally fits all applications, regardless of pressures and volumes involved in the systems, I stand corrected.
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post #9 of 26 Old 01-10-2018, 12:03 PM
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Tusk Rotor with SS Line makes the Front Brake "acceptable."
This is hardly a ringing endorsement; but it's certainly a far cry from what came on the bike from Kawasaki!

Last edited by Bluehighways; 08-31-2018 at 01:20 AM.
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post #10 of 26 Old 01-10-2018, 01:23 PM
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Quote:
Originally Posted by Damocles View Post
You may not "need" to replace the master cylinder when adding a dual-cylinder caliper but . . . expecting identical performance from master cylinders of different designs and operational capabilities contradicts the laws of hydraulics as I understand them. The old master cylinder may function with a dual-cylinder caliper, but . . . optimally? I doubt it.

Kawasaki installed re-designed master cylinders to match Generation 2 dual-piston front calipers; did not "re-purpose" Generation 1 master cylinders for the purpose.

If, however, one master cylinder optimally fits all applications, regardless of pressures and volumes involved in the systems, I stand corrected.
In theory, you are correct.....in practice you are wrong; the proof is in the pudding - myself and many others are using the SV caliper with the stock Gen1 master and it works great. Optimal? No, probably not but this is all a big guessing game using parts from other applications. I suppose you could try an SV master too, but again, it works great with the stock Gen1 master.

I assume you've all read the 21 page thread on .Net on this subject?....

you said that you won't get "the advantage of a dual piston caliper" without a MC change; this is wrong in this case.


Dave
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