Front Caliper..Red Alert - Kawasaki KLR 650 Forum
2008+ KLR650 Wrenching & Mod Questions For repair, maintaining or modifying discussions related to the newly updated 2008 and beyond, Generation 2 KLR650 Motorcycle.

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post #1 of 12 Old 04-05-2013, 09:38 AM Thread Starter
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Front Caliper..Red Alert

So I am looking at my trusty KLR last night. The front brake has got a little soft if the last few days and I notice my front rotor is black? What the heck? On closer inspection I find the caliper is leaking just a bit and the pads are damp. Great...Its a KLR however.... SO this begs the question, I have been thinking about replacing the front brake line with a braided peice and now The Caliper is leaking. Does someone make a rebuild kit for these calipers or is it worth it? I dont even know what they cost.
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post #2 of 12 Old 04-05-2013, 09:49 AM
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You can buy the seals to rebuild the caliper at the dealership. They don't cost much. Replace the pads and clean up the rotor. There are numerous options for improving the brakes which I'm sure you'll hear about. Replacing the brake line is a simple improvement. From there the price goes up. Depends on how satisfied you are with the braking.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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Last edited by klr4evr; 04-05-2013 at 11:15 AM.
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post #3 of 12 Old 04-05-2013, 10:31 AM
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OR, now is the perfect time to upgrade....well that is if you have the 320 rotor already. Didn't think before posting.....if you do, you can get a print out of the bracket you need to make to add a Vstrom caliper that will give you much better braking power over the stock caliper. Ebay is your friend.....Vstrom 1000cc front left caliper. It bolts directly to our stock hose.

Just a thought.......then if you want to go one more step, a CBR600RR master bolts directly onto the bars and the stock line as well. Giving you now the next best thing on top of the Vstrom caliper and a 320 disc. Thsi set up will give you prper street bike brakes. Plus the master is a radial master with adjustable lever for street and gravel feel so it doesn't lock u the brakes.

It truly is the best set up for our bikes. .....ask me how I know. I have been running this set-up for a few years now and it's lets just say FANTASTIC!!!

Willys
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post #4 of 12 Old 04-05-2013, 10:36 AM
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Repair or replace, your choice, moriver!

If you're satisfied with the OEM brakes, disregard; since you consider a steel-braided brake line, perhaps you're not!

My experience; I installed an EBC oversized rotor (320 mm?) and stainless-braided front brake line on my Generation 1; profound difference; improvement in controlling stopping, IN MY EXPERIENCE, perception and discernment! Generation 2s come with larger rotors and dual-piston calipers; the improvement would not be noticeable on the later models, I'd think.

Wouldn't make any bets on shortened stopping distances, but . . . the braided line makes the caliper respond immediately to the brake lever; no "squish," as with the OEM rubber tube. The faster response means shorter distance traveled 'til the caliper grabs the disk, seems to me.

The oversized rotor may offer more stopping power leverage, but . . . its main advantage appears to me to be the improvement in modulation of braking; control if you will--the degree and timeliness of the braking action seems much more up to the rider.

Oh, yes; YMMV!

Last edited by Damocles; 04-06-2013 at 05:24 AM.
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post #5 of 12 Old 04-05-2013, 11:18 AM Thread Starter
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Quote:
Originally Posted by willys View Post
OR, now is the perfect time to upgrade....well that is if you have the 320 rotor already. Didn't think before posting.....if you do, you can get a print out of the bracket you need to make to add a Vstrom caliper that will give you much better braking power over the stock caliper. Ebay is your friend.....Vstrom 1000cc front left caliper. It bolts directly to our stock hose.

Just a thought.......then if you want to go one more step, a CBR600RR master bolts directly onto the bars and the stock line as well. Giving you now the next best thing on top of the Vstrom caliper and a 320 disc. Thsi set up will give you prper street bike brakes. Plus the master is a radial master with adjustable lever for street and gravel feel so it doesn't lock u the brakes.

It truly is the best set up for our bikes. .....ask me how I know. I have been running this set-up for a few years now and it's lets just say FANTASTIC!!!
Well now this sounds like a good time...I think I will Just reseal the thing and the start collecting parts willys. This with a fork update might be the trick....
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post #6 of 12 Old 04-05-2013, 11:20 AM
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Quote:
Originally Posted by willys View Post
you can get a print out of the bracket you need to make to add a Vstrom caliper that will give you much better braking power over the stock caliper. Ebay is your friend.....Vstrom 1000cc front left caliper. It bolts directly to our stock hose.
Where is this "print out" available from???

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

"It's a friggen motorcycle, it's not supposed to be comfortable, quiet or safe. The wind noise is supposed to hurt your ears, the seat should be hard and riding it should make you shit your pants every now and then. "

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post #7 of 12 Old 04-05-2013, 12:59 PM
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Damn...I thought I saved it....I have a template for it, but the print out is over at .net. Good luck....lol.
Search "how I fixed my brakes for $21".

Willys
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post #8 of 12 Old 04-06-2013, 05:55 AM
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Quote:
Originally Posted by willys View Post
Damn...I thought I saved it....I have a template for it, but the print out is over at .net. Good luck....lol.
Search "how I fixed my brakes for $21".
Would a Vstrom 1000 cc front brake caliper bracket for a Generation 1 KLR650 fit a Generation 2 KLR650?

If so, great! With the changes (i.e., single-piston to dual-piston caliper; larger-diameter rotor), I wondered if the "Frankenbike" bracket were upwardly compatible.
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post #9 of 12 Old 04-06-2013, 07:23 AM
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This a Gen 1 mod only as no-one has made the bracket for the Gen 2 yet.

Willys
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post #10 of 12 Old 04-06-2013, 09:06 AM
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I did a pretty basic upgrade; just the braided line. It helps. Also put on some sintered EBC pads. That helped also. I did have to replace the rubber seals in the caliper. One of them got torn and the piston stopped moving. It's a whole new world driving across town at night with no front brake!
As long as I had the caliper apart I installed a Spiegler Speedbleeder bleeder screw. That didn't do anything for the performance of the brakes but it sure makes it easier to flush the system.
Do remember to refill with FRESH brake fluid. I was thinking "gee I only used a few ounces from this bottle I bought last year" and then I thought "ok, what's another 5 bucks compared to not being able to stop?".
Dear old Dad has always told us kids not to be tightwads when it comes to healthcare, education, and brakes.
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