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GPz900R Brake Caliper Assembly
August 2007
August saw the rebuild of the front calipers take place. I ordered the parts from the GPz Zone in the UK and they arrived within a week or so. Its a simple job to assemble the calipers when the parts are clean, so I recommend that you do that when you get any part of the bike. First lay out all the parts from the rebuild kit and insert the first smaller gator and then get the rubber grease out. I use a Castrol rubber grease designed for assembling brake systems (Its a distinctive RED color) and they only make one type for brakes.
August saw the rebuild of the front calipers take place. I ordered the parts from the GPz Zone in the UK and they arrived within a week or so. Its a simple job to assemble the calipers when the parts are clean, so I recommend that you do that when you get any part of the bike. First lay out all the parts from the rebuild kit and insert the first smaller gator and then get the rubber grease out. I use a Castrol rubber grease designed for assembling brake systems (Its a distinctive RED color) and they only make one type for brakes.
After the smaller gaiter is installed you can start on the O-Rings. The first thing I do is to use a brake rubber grease to coat the O-rings with then insert them (there is a think one that seals the brake fluid and a thinner one that keeps out the dust etc. Then put some brake grease on the piston and carefully push it in evenly.
The next step is to install the other gaiter, its different as its longer so it needs be greased up to slide in cleanly (so to speak). I use a philips head screw driver to push it in SLOWLY and carefully, I would use a flat shaft rod if I had one handy. If you are reusing old parts then you should NOT use a screw driver as it will most likely puncture through.
With both gaitors on (and greased), grease up the caliper mounting plate. This plate has been cleaned and clear coated with a marine clear polyurethane. You could also powder coat it or for something different gold zinc or chrome plate it. Either way it needs a reasonable amount of grease on its end and then you need to slide it in. I make sure the grease spreads evenly in the slide so move it back and forth a few times.
The last step is to install the stainless steel spring retainers. This consists of a spring plate and two smaller plates which can be seen on the left and right of the pad (look at the previous photo to identify the spring plate clearly). The two pad retainers clip onto the caliper body so that the pad can sit into them (they have two small fingers that the pad sits against). Once the stainless retainers are installed, the sliding pad can be pushed in (as shown), it has a key way that stick out and cannot be seen in the photo but is pointing down.
The picture shows the assembled unit prior to the fixed pad being installed. It goes in at an angle and also has a keyway that pushes against the spring plate.
In all it should take about 5 minutes a calliper to put together.
The picture shows the assembled unit prior to the fixed pad being installed. It goes in at an angle and also has a keyway that pushes against the spring plate.
In all it should take about 5 minutes a calliper to put together.
The assembled units, as you can see there is plenty of room to slide a disk in.
The rear calliper is pretty much the same but mounts differently. You can also use GPz750 Callipers but the mounting plate is different (it is pointy at the top while the 900 has a flat spot).
The rear calliper is pretty much the same but mounts differently. You can also use GPz750 Callipers but the mounting plate is different (it is pointy at the top while the 900 has a flat spot).
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