Front caliper swop - Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R
 
LinkBack Thread Tools
post #1 of 25 (permalink) Old 10-24-2015, 2:20 PM Thread Starter
Member
 
Join Date: Oct 2010
Posts: 47
 
Front caliper swop

How do all

Does anyone know if any other front caliper fits straight onto a 96 model Gpx/Ex?

I'm thinking a right caliper off of a ZXR

And yes I know it'll be an overkill with the braided line I already have but I just love to tinker

Cheers, Cloot
Cloot is offline  
Sponsored Links
Advertisement
 
post #2 of 25 (permalink) Old 10-24-2015, 7:27 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

er6n fits
lunty74 is offline  
post #3 of 25 (permalink) Old 10-24-2015, 7:47 PM
Senior Member
 
Join Date: Dec 2014
Posts: 1,375
 
Re: Front caliper swop

Quote:
Originally Posted by lunty74
er6n fits
But is it better?

Chicago, IL - Cincinnati, OH
urbane is offline  
 
post #4 of 25 (permalink) Old 10-24-2015, 9:15 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

old ex caliper .........new er6n
Attached Images
File Type: jpg DSCF9088.2.jpg (190.8 KB, 52 views)
File Type: jpg DSCF9128.2.JPG (236.7 KB, 55 views)
lunty74 is offline  
post #5 of 25 (permalink) Old 10-25-2015, 12:24 PM Thread Starter
Member
 
Join Date: Oct 2010
Posts: 47
 
Re: Front caliper swop

But is it a four potter or just another two pot caliper?
Cloot is offline  
post #6 of 25 (permalink) Old 10-25-2015, 1:00 PM
Super Moderator
 
K-woppa's Avatar
 
Join Date: Mar 2012
Location: SE MA
Posts: 3,455
 
Re: Front caliper swop

Four pot calipers are not a bolt-on for the ex500. It would require adapter brackets and, IMO, some machining on the fork bosses, due to offset issues. I don't know if there is enough supporting material on the fork tubes to allow them to be cut back enough to make it work. If I still had an ex500 I would have explored this further, because four pots are a nice upgrade, better feel and increased ultimate braking power. But honestly, properly set up, the stock caliper does a pretty good job on such a light bike.
K-woppa is offline  
post #7 of 25 (permalink) Old 10-25-2015, 5:08 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

Quote:
Originally Posted by Cloot
But is it a four potter or just another two pot caliper?
its only a twin pot caliper
lunty74 is offline  
post #8 of 25 (permalink) Old 10-25-2015, 5:13 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,065
 
Re: Front caliper swop

It would only be worth doing if you could mount a opposed piston type. any with sliders of any type are worthless.
Even then the disc must be floated to eliminate conning.

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #9 of 25 (permalink) Old 10-26-2015, 1:32 PM
Senior Member
 
jorge moros's Avatar
 
Join Date: Nov 2014
Posts: 778
 
Re: Front caliper swop

Would not it be better to use double disc brake as European models?

Only two things are infinite, the universe and human stupidity, and I'm not sure about the former. -Albert Einstein.
2007 Ninja 500R
jorge moros is offline  
post #10 of 25 (permalink) Old 10-26-2015, 1:50 PM
Senior Member
 
Join Date: Jan 2015
Posts: 134
 
Re: Front caliper swop

What all would really be needed for a gpz500 dual disk swap?
Mgalutia88 is offline  
post #11 of 25 (permalink) Old 10-26-2015, 2:51 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,065
 
Re: Front caliper swop

Not any better ask the limies.

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #12 of 25 (permalink) Old 10-26-2015, 3:17 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

I'm doing a twin fork set up , the twin disc wheel and forks where only sold in Germany ( so that is where u need to look for a set ) the early 16 " wheel mine are 1989 , brake callipers are twin large single pots ... but iv been running an idea to swap them to a set of single disc ex500 callipers I am the few that think the stock callipers are fine
. just because I have a single disc wheel on , so would be economical to just get a caliper from a gpz 500 d model with the brakes mounted on the right
lunty74 is offline  
post #13 of 25 (permalink) Old 10-26-2015, 3:24 PM
Senior Member
 
FTL900's Avatar
 
Join Date: Aug 2013
Posts: 105
 
Re: Front caliper swop

I did a front end swap once, bolted on an Interceptor 500 front end with twin discs, because I had one and the EX500 needed new forks.
Had to mill the triple clamps 1mm for larger fork tubes, and then I slid the Honda front end into the Kawi triples. Kept the Honda front brakes and master.

ZRX1100, Bandit 1200S, GS500
FTL900 is offline  
post #14 of 25 (permalink) Old 11-30-2015, 4:21 PM
Senior Member
 
Join Date: Dec 2009
Posts: 372
 
Re: Front caliper swop

r1 disk adaptorplate cbr600 caliper 4 pot works great
Attached Images
File Type: jpg screen saver.jpg (116.7 KB, 43 views)
moocatdog is offline  
post #15 of 25 (permalink) Old 11-30-2015, 6:05 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,065
 
Re: Front caliper swop

The big issue is the ridged disc not the caliper so much.
Replace it with a floater and you'll get a real improvement

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #16 of 25 (permalink) Old 12-1-2015, 8:41 AM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

if I didn't have the 16" twin forks I wouldn't have attempted this , and after trawling for days I purchased 2 gpz 750 front brake discs (same dimensions as the EX500) and a pair of ex650 front brake callipers
Attached Images
File Type: jpg $_57ZT934UW1.jpg (564.4 KB, 17 views)
File Type: jpg $_57PIXWJLU2.jpg (508.0 KB, 14 views)
File Type: jpg $_57RXHDMLAU.jpg (51.3 KB, 15 views)
File Type: jpg $_57AD92CIO8.jpg (50.0 KB, 11 views)
File Type: jpg $_575G5R11T3.jpg (56.3 KB, 12 views)
lunty74 is offline  
post #17 of 25 (permalink) Old 12-1-2015, 8:44 AM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,065
 
Re: Front caliper swop

Good deal, now you have two lousey brakes.
This is one case where twice as many doesn't equal double.


FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #18 of 25 (permalink) Old 12-1-2015, 2:29 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

Quote:
Originally Posted by FOG
Good deal, now you have two lousey brakes.
This is one case where twice as many doesn't equal double.


FOG
when I rode the ex650 I liked the front brakes and handling , but its got a bigger front wheel and discs .... the brakes that came with the forks I bought are the large single piston type and are well past there time and function , so tried to find a ex5 calliper and rotor from a right side mounted fork and use my single calliper . either too costly in shipping or 1-2 mm from minimum wear limit , and last I looked at the sv650 front brakes but budget wouldn't stretch that far
lunty74 is offline  
post #19 of 25 (permalink) Old 12-1-2015, 4:01 PM
fog
Senior Member
 
Join Date: Oct 2006
Location: Mt home, AR
Posts: 19,065
 
Re: Front caliper swop

One good (iron) floater disc and a set of HH sintered pads will out stop all that junk, on my rave bike I could howl the front tire or lift the rear at will.

FOG

I hate PMs if you want to contact me, find my email address.Look in the for sale section.
fog is offline  
post #20 of 25 (permalink) Old 12-1-2015, 5:02 PM
Senior Member
 
Join Date: Nov 2013
Posts: 1,334
 
Re: Front caliper swop

iv got that combo on the bike now and have no complaints ... its just I have the twin forks wheel Tyre and brakes a spare frame with the air shock from a gpz 600 ninja 600. so if I don't put them on my bike ill be using it on that , seems a pity to scrap the frame just because a accident made it a cat C write off(wreck) iv the majority of parts to get a rolling chassis .. now iv just had my brain implode due to the heavy formula involved in working out fluid and dynamic motion ..lol my Haynes my manual is no help and prob only Kawasaki engineers would have the relevant information id like to find out how the frame would do with a engine that's 11 lbs heavier than the ex but also pumps out 52kw of torque ...I know our bikes is 37.2 kw the variables involved are massive , and I don't know the bikes parameters for stock , the custom build would be cosmetic due to the use of a VFR 400 pro-arm with dimensions of swing arm mounting width . 192mm ours is 202mm spindle diameter is 17mm ours 22mm 18" rear wheel ... the vfr 400 also uses the 16" front wheel ... there is a couple of ninja 250s and ZXR750 that have a single side swing arm but couldn't find any ex 500 .... I suspect because ..1-no one has attempted it ( highly unlikely ) or 2 they have don't it but the results where a bike that's un controllable and ride .
next headache will be the mono shock , mounting ,dimensions , geometry ,
lunty74 is offline  
post #21 of 25 (permalink) Old 7-8-2019, 11:14 AM
Junior Member
 
Onyx's Avatar
 
Join Date: Apr 2019
Posts: 4
 
I tried a Honda VFR400 4 pot caliper on my old single disc gpz500 '98 model, i made my own adaptor, used with standard disc. It was a bit better but not amazing. Later i tried a Honda VTR 1000 4 pot calliper paired to a Yamaha R1 4xv disc, that was pretty decent! As much power as i' d risk on the mounting posts on the forks. I had to machine the calliper mount as well as make my own adapter again but this was worth it. Ill post pics below.
Attached Images
File Type: jpg 196927_10150204909977729_636072728_8993890_3366947_n_1562598614156.jpg (75.6 KB, 13 views)
Onyx is offline  
post #22 of 25 (permalink) Old 7-8-2019, 11:15 AM
Junior Member
 
Onyx's Avatar
 
Join Date: Apr 2019
Posts: 4
 
Honda Vtr1000 4 pot calliper and a yamaha r1 4xv disc. Done by myself.
Attached Images
File Type: jpg 20120303_151622_1562598895590.jpg (439.4 KB, 16 views)
Onyx is offline  
post #23 of 25 (permalink) Old 7-8-2019, 11:18 AM
Junior Member
 
Onyx's Avatar
 
Join Date: Apr 2019
Posts: 4
 
R1 4xv disc is a direct fit, drill the homes out to 9.9mm diameter to fit snug on the m10 disc bolts. I had to machine the inner face of the VTR1000 calliper and drill through the tapped holes, then make up an adaptor to bolt it to the bike.
Attached Images
File Type: jpg 20120303_163946_1562599015251.jpg (517.5 KB, 15 views)

Last edited by Onyx; 7-8-2019 at 11:35 AM.
Onyx is offline  
post #24 of 25 (permalink) Old 7-8-2019, 8:16 PM
Super Moderator
 
K-woppa's Avatar
 
Join Date: Mar 2012
Location: SE MA
Posts: 3,455
 
Quote:
Originally Posted by Onyx View Post
R1 4xv disc is a direct fit, drill the homes out to 9.9mm diameter to fit snug on the m10 disc bolts. I had to machine the inner face of the VTR1000 calliper and drill through the tapped holes, then make up an adaptor to bolt it to the bike.
I did a four pot conversion four years ago on my Concours, and at the time I decided to scope out if a bolt-on swap would work for the ex 500. It looked like the most viable option was machining the fork bosses and mounting the adapter plate outside the forks. At that point I didn't look into it any further because the ex was for sale, but I've remained curious about it.

I seem to remember there wasn't enough clearance to mount the adapter inside the forks but it looks like you do have your adapter plate inside. Can offer a few more particulars on how you pulled off this swap?
K-woppa is offline  
post #25 of 25 (permalink) Old 7-9-2019, 4:19 AM
Senior Member
 
Join Date: Nov 2017
Location: England UK
Posts: 413
 
Garage
hi, the adapter plate will work on the inside providing it's not too thick. but there is a easier way been done here in the UK a few times.


right fork leg of the GPZ500 [gen 2] left fork leg bottom off the ER500 both 37mm. twin disc front wheel some use GPX/GPZ 600 270mm EBC floating discs CBR callipers. connected by SS brake hoses. you end up with a brake that's so keen your scared to use it.
yorkie is offline  
Reply

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Ex-500.com - The home of the Kawasaki EX500 / Ninja 500R forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in










Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page



Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome