Adventure 320mm Single Rotor Conversion w/ STOCK caliper

Discussion in 'Crazy-Awesome almost Dakar racers (950/990cc)' started by Johnf3, Mar 19, 2012.

  1. brents347

    brents347 Trusting my Cape...

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    I have a couple of different ones for different wheels. One I have is off my 660 rally bike, and one I had custom cut as a 320mm disc with the center spacing/bolt pattern to match my SM mag wheels.

    I'll get a 320 mounted up today or tomorrow and post pics. Also, as soon as my ST1100 pads arrive (tomorrow) I will post pics of the modification required.
    #81
  2. Johnf3

    Johnf3 Long timer

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    Good work. I wonder if there is a pad that will fit the caliper without any filing needed. I'll order one up too as long as you can get the ST pads to go in.

    I think the front rotor bolt patterns for the KTMs are mostly all the same, so most any 320mm disc should work.
    #82
  3. Balsta

    Balsta Been here awhile

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    :clap:clap:clap:clap:1drink:1drink:norton:norton MORE PHOTOS ON THE COMPLETE STUFF!
    #83
  4. brents347

    brents347 Trusting my Cape...

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    [​IMG][/IMG]

    [​IMG][/IMG]

    [​IMG][/IMG]


    So here's a few photos of the brake with a 320mm disc mounted.

    And looking for the ST1100 brake pads today, I have some news. I can find the pads on e-bay, but nowhere else. I want a simple pad that I can find easy just about anywhere, so I went hunting again. It turns out the pad from VFR800 is exactly the same, it is just .6mm thicker. I was concerned about this because the pads willbe a total of 1.2mm thicker now, but looking at my caliper tonight it looks like i have plenty of room for a slightly thicker pad. I have some coming and they should be here tomorrow.
    I'll keep you posted as it comes together.
    #84
  5. brents347

    brents347 Trusting my Cape...

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    So here's the latest from today.

    I spent some time working on how well the front wheel free spins. With no brakes on, it spins about 14 times with one good pull. With the caliper on, it only spun about 1 1/2 turns. I have always been big on havng a bike tht freewheels well, so then I spent some time figuring out why the wheel didn't spin more.

    After much experimenting, I found 2 things. One, the caliper sliding pins are not mounted perfectly straight so by turning one pin 1/2 turn out and the other 3/4 turn out, I got it spinning better. Secondly, I found that the caliper, when mounted to the caliper bracket, was not hanging perfectly straight so there was alays a slight brake pad drag on the rotor after pulling the brake lever. I fixed this by shimming the caliper slightly on the bracket. The bottom caliper bolt needed a slight shim. Now it spins 4 full turns with one pull just after having pulled the brake lever. I am very happy with this. I haven't figured out how to do the shimming permanently, but I will work on it.

    I should have the brake pads tomorrow.
    #85
  6. brents347

    brents347 Trusting my Cape...

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    Also today I got my new front wheel built. It is a Talon hub with bearings and seals, mounted (by Woody) to a new 1.6" excel wheel and I'm running a new Dunlop 606 with a Tubliss system. The total wheel with the 320mm rotor was 3.4lbs. lighter than my stock wheel running a Super Scor and tube and a 300mm rotor. Not a bad reduction in unsprung weight off the front wheel!

    Next I started to mount up my new set of SM mag wheels to the bike. With the 320mm rotor I had made for these wheels I can just BARELY get the caliper back on. It barely fits between the rotor and the outside of the rim. But it fits! Now I need to have some custom spacers made for both sets of wheels.
    #86
  7. brents347

    brents347 Trusting my Cape...

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    Well I am happy to say I was able to make it work. Here's a couple details of the pads.

    First pic is a new set of 950 SE pads, a set of the VFR 800 pads, and one of my old, modified SE pads.
    [​IMG][/IMG]

    Then this one is the new pads with the old SE pads laid on top for comparison.
    [​IMG][/IMG]


    This one shows the pads installed in my caliper after having the ends filed down about 3mm.
    [​IMG][/IMG]

    And here is the finished product. I haven't ridden it yet because there is no back half installed on the motorcycle, but I'm really happy with how it came out.
    [​IMG][/IMG]
    #87
  8. jimmibanke

    jimmibanke Been here awhile

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    Hi

    I havent read the entire post, but this works just fine for me, i can block the front even with heavy load so the power is there... And the control is okay. Its a cheap fix, around 50$ in total.

    I have removed one caliper, and mounted a new wave disc, nothing more. Cheers:)

    [​IMG]
    #88
  9. Dr LC8

    Dr LC8 ...soon or later

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    Hi,

    What dick is that? How much does it cost? What are the $50 for? It can't be the disck?

    Nic
    #89
  10. jimmibanke

    jimmibanke Been here awhile

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    I got the disc from ebay, slightly used but nothing to see on it, i was lucky, but you can buy a new galfer wave disc on ebay for around 120£ in germany or england. Cheers
    #90
  11. brents347

    brents347 Trusting my Cape...

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    That's a good point about cost. For the record, I am $43 into the brake pads and $63 into the relocation bracket. The 320mm rotors can be pricey, but you have a lot of options for those.

    There are always cheaper ways to do things, but I didn't want to stay with a 300mm rotor. Particularly with my SM wheels and sticky rubber. I had gotten a 320 rotor to work on my last Adventure and loved the braking so that is why I did it again.
    #91
  12. Balsta

    Balsta Been here awhile

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    Anybody yet to supply a 320 mm "kit"? Well, 2 kits since I am finally into getting a 19'/17' wheelset for my SE to quit being forced to compromize on tyres, on gravel and on tarmac as well. Lucas, are you still putting together a set of such wheels? PM! I also need to find out the maximum possible rim- and tyrewidth front and rear without scraping the fork/swing.
    #92
  13. brents347

    brents347 Trusting my Cape...

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    No kit yet that I know of, but I have stopped looking. I haven't heard any chatter here though.
    #93
  14. LocuL

    LocuL Gnarly Infantry

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    I´m running 320mm and the adapter on my project. It is very strong. Feel is fine to.
    #94
  15. Balsta

    Balsta Been here awhile

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    Did you set it up as brents347 did? With grinding of some millimeters on selected pads?
    #95
  16. LocuL

    LocuL Gnarly Infantry

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    Yes my friend that is correct.

    Stoppingpovver vvith 60litre of fuel, me and some luggage. 1 finger vvill do the job, 2 fingers vvill make the thing stoppie as needed.

    :clap
    #96
  17. Chico Ryan

    Chico Ryan noslo1

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    CJ, I would buy one! Looking to convert to the 320 as well for the SE
    #97
  18. brents347

    brents347 Trusting my Cape...

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    Ryan,

    This is a basic one. Buy the bracket and a pair of the brake pads I listed above and ride it up to Truckee. We can do it in an hour. Oh, should probably buy a rotor as well!

    Brent
    #98
  19. max2

    max2 Been here awhile

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    Brent's, over the stock SE stuff...how much better is the 320mm rotor?
    #99
  20. brents347

    brents347 Trusting my Cape...

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    It's a little hard to equate.

    On 17's with sticky rubber I can get the bike to do stoppies. Not easy at 450 lbs. or so! With the 21" front (on which I only run knobbies) I can easily lock the front on pavement and yet it is very easy to modulate in the dirt. Does it stop super quick on dirt? No, but again it is 450 lbs. with momentum on dirt! :lol3

    I like having too much brake rather than too little. When I put a 19"/17" set-up and DS tires on my 950 SM people thought the brakes would way over-power the tire but it worked great for me.

    I would say that the 320mm conversion is a 20-25% improvement over stock braking. But I have nothing to back that claim up. :D