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Old 05-31-2014, 10:24 PM   #1
Tony T OP
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Calling All DR600 Owners

I just went for my first ride on my 1989 DR600 and the front brake is terrible!
Someone told me it would be before I rode the bike, but I didn't think it would be that bad. It is..........
Can anyone offer any words of wisdom on how it could be improved?
I've looked around for an oversize disc but there doesn't seem to be one available to suit but the rotor off my 750 looks like it will fit and is quite a bit bigger. I'd really rather not swap the whole front end over if I can help it as it would mean grinding off the steering stops and welding new ones, but if nobody has got any better suggestions, I guess I could go that way.
Thanks in advance.

Tony T screwed with this post 06-03-2014 at 03:29 AM
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Old 06-03-2014, 03:28 AM   #2
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Bump.
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Old 06-03-2014, 06:55 AM   #3
wsmc831
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No idea on your exact setup, but I remember my 91 cr250 being lousy as well, probably a function of age and design.

Start with the basics. Good scotchbrite or similar cleaning of the rotor, new aggressive pads, fresh fluid. Larger rotor will require caliper relocation bracket, but I would doubt one is available for that bike. Maybe there are parts off a newer DR that would bolt up?
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Old 06-03-2014, 08:41 PM   #4
Tony T OP
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Thanks for the input, mate.
I've done the basics but haven't tried a different type of pad.
I'll give that a go, but it's looking like the single piston caliper is the main culprit and I might have to do the change to the 750 front end.
Bummer.....
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Old 06-04-2014, 11:37 AM   #5
MrPulldown
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Brake pads and rotors are glazed.
The first thing to try before spending money is to hit the pads and rotors with sand paper.
-Remove pads. Lay a sheet of 150-200 grit on the bench. Grind away until groves and shiny surface is gone.
-Make sure the piston moves in and out smoothly. Lube the guide pins. Or hit steel wool.
-Take some finer grit sandpaper 3-400 ish. Tear a small section of sand paper. Make circular motions on the rotor. Try to get it so that the groves are gone or at least till they have a dull even hue. Do both side.
-Flush system with new brake fluid. Do not get any on the rotor or pads. Might do this before sanding when the pads are removed.

If this does not give you satisfactory results THEN considered upgrading.
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Old 06-04-2014, 03:10 PM   #6
Tony T OP
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Quote:
Originally Posted by MrPulldown View Post
Brake pads and rotors are glazed.
The first thing to try before spending money is to hit the pads and rotors with sand paper.
-Remove pads. Lay a sheet of 150-200 grit on the bench. Grind away until groves and shiny surface is gone.
-Make sure the piston moves in and out smoothly. Lube the guide pins. Or hit steel wool.
-Take some finer grit sandpaper 3-400 ish. Tear a small section of sand paper. Make circular motions on the rotor. Try to get it so that the groves are gone or at least till they have a dull even hue. Do both side.
-Flush system with new brake fluid. Do not get any on the rotor or pads. Might do this before sanding when the pads are removed.

If this does not give you satisfactory results THEN considered upgrading.
Thanks mate, but as I mentioned above, I have done all that.
So I am considering upgrading..........
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Old 06-04-2014, 10:09 PM   #7
lost1
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The dr 600 front brake is horrible (still better than the same vintage KLR). I tried everything including braided lines and master cylinder, caliper rebuild. The problem as mentioned is the piston is small and just doesn't hold up to the weight of the bike and it's made worse with a little rotor that heats up fast You could try to upgrade the master cylinder with something stronger to get a bit more force on the caliper.

I made it around the world on mine, but I went through several pairs of boots...
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Old 06-05-2014, 02:17 AM   #8
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Originally Posted by lost1 View Post
I made it around the world on mine, but I went through several pairs of boots...
You're not Udo's mate, Harald are you?
Regardless, thanks for the first-hand information.
I think I'll bite the bullet and use the DR750 stuff I have. It will need rebuilding and a new rotor, but hopefully it's worth it in the end.
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Old 06-05-2014, 05:17 AM   #9
RealOldDualSportGuy
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Front Brake

Braided Front Line

Aggressive Pads

New Fluid

320 mm Rotor

Replace master cylinder

Good Luck


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Old 06-05-2014, 04:09 PM   #10
robszombie
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Try http://www.dr-big-shop.de/DR_600.html, Stephan sells all sorts for DRs. He's the King wrt knowledge.
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Old 06-06-2014, 04:11 AM   #11
Tony T OP
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FYI I found a braided line in the shed today and gave it a try.
It was an improvement, but not by much.
I think I need to bite the bullet and just fit the 750 front end that I have.
The fork springs in that should cope better with the 38 litre fuel tank as well.
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Old 06-08-2014, 09:26 AM   #12
lost1
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Quote:
Originally Posted by Tony T View Post
You're not Udo's mate, Harald are you?
Regardless, thanks for the first-hand information.
I think I'll bite the bullet and use the DR750 stuff I have. It will need rebuilding and a new rotor, but hopefully it's worth it in the end.
Nope, I don't know Harald. I do love my 88 dr 600 more than any other bike I've owned. I have well over 200 000 klms on it with just one top end rebuild. Almost every kilometer was in underdeveloped countries.
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