R100GS Nissin 4-piston caliper conversion

Discussion in 'Airheads' started by Solo Lobo, Apr 7, 2005.

  1. XR200

    XR200 n00b

    Joined:
    Mar 20, 2008
    Oddometer:
    6
    Hi everyone,

    I'm new here and have been reading this article with interest.
    Now my question is can this set up be used on a monolever G/S, that is the caliper is behind the fork leg and also the wheel is different. I think that the clearence between the spokes and the inside half of the caliper may be to close, the standard caliper is very close to the spokes so a better caliper would need to be no bigger (wider) than standard.
    All replies will be appreciated greatly.

    Ian.
  2. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,659
    Location:
    Shoreline, WA
    Ian,

    Going through this question now, check my thread "I sold my bike and then went shopping"
  3. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,659
    Location:
    Shoreline, WA

    Upon further review.... it looks like I can mill 4mm off of the lower mounting ear on a k-bike 4-piston caliper and then mill some kind of adapter for the upper lug then, you can do the same kinda deal..

    I will try and sneak into the shop at work and mill my caliper, and if all goes well I can figure out the adapter needed.... finger crossed :norton
  4. lesman

    lesman Live easy, Brake Hard

    Joined:
    Sep 7, 2006
    Oddometer:
    2,368
    Location:
    Houston, Texas
    Solo,
    What caliper is on the G/S? Is it the same as a GS? The 4 piston brembo off a Gs11xx should fit. I used one before I went to the land of Tokico.





    Les
  5. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,659
    Location:
    Shoreline, WA
    The one I have is a K12 something or other...
  6. x3300

    x3300 geoff

    Joined:
    Mar 31, 2005
    Oddometer:
    170
    Location:
    San Jose, CA
    Hi,

    I had an adapter made so I could mount a 320mm disk from a Ducati. I now have a late model 4 piston BMW (Brembo) caliper, but at first I used the stock GS caliper, and it worked very well with the big disk. Send me a mail if you want more info or photos.

    -x3300
  7. johno

    johno Long timer

    Joined:
    Dec 31, 2007
    Oddometer:
    2,913
    Location:
    Mount Gambier, South Australia, Australia.
    x3300, I think quite a few of us would be interested in this setup.
    What model ducati did the disc come from?
    How about posting any info up here.
    Looks good.:D
  8. richarddacat

    richarddacat Rollin' and Tumblin'

    Joined:
    Nov 22, 2006
    Oddometer:
    4,096
    Location:
    Heart of Tennessee
    :thumb
    oooh, I like that :thumb

    been wanting to get my solid disc drilled somewhere but I would like to see more on your little mod,

    PM if you rather. :lurk
  9. x3300

    x3300 geoff

    Joined:
    Mar 31, 2005
    Oddometer:
    170
    Location:
    San Jose, CA
    I'll need to dig up the info, but I'll make a post that tells how I did it. Until then, here is another photo.
  10. XR200

    XR200 n00b

    Joined:
    Mar 20, 2008
    Oddometer:
    6
    I will look forward to your results on the K12 caliper and thanks for directing me to your other thread.
    That is a very worthwhile and interesting project you have there.
    Thanks again Ian.
  11. lesman

    lesman Live easy, Brake Hard

    Joined:
    Sep 7, 2006
    Oddometer:
    2,368
    Location:
    Houston, Texas
    Solo:
    Are the G/s and the GS calipers the same?





    Les
  12. XR200

    XR200 n00b

    Joined:
    Mar 20, 2008
    Oddometer:
    6
    I think the mounting holes are spaced differently, don't know about any other differences but they look very similar. Really they need to be compared side by side and I only have G/S caliper to hand.
  13. Solo Lobo

    Solo Lobo airhead or nothing

    Joined:
    Mar 16, 2004
    Oddometer:
    9,659
    Location:
    Shoreline, WA
    Yes, the are different. The 4-piston K caliper will bolt right onto a R100GS after milling the ears... the G/S slider boss's are furthe appart then the GS
  14. x3300

    x3300 geoff

    Joined:
    Mar 31, 2005
    Oddometer:
    170
    Location:
    San Jose, CA
    This write up describes my experience trying to enhance the front brake of my 1993 R100GSPD.

    At first I looked at some aftermarket brake kits for the GS, but then decided a better solution was to fit a big disk from a bike that was easy to source. I did some research in the aftermarket brake parts catalogs, looking at disks for Honda, Yamaha, etc., and found that the standard Ducati 'snowflake' disk had the dimensions that I though would work with a simple adapter. I found there are many aftermarket parts available at a range of prices, but I chose the EBC model MD2003C as a kind of middle of the range part. There are just a few sizes that fit all the Ducati models, and here is what I found out about that snowflake disk:

    Code:
      1995 Ducati 916 SP
      diameter    320
      thickness   5.0
      offset      9.65
      bore        64.0
      bolt circle 80.0
      bolt dia    8.5
      bolt count  6
    
    This is what I measured the GS to be:

    Code:
      bore        62.0
      bolt circle 79.0
      bolt dia    10.0
      bolt count  4
    
    I made a drawing, bought some aluminum stock and had a machine shop make the adapter. The drawing and shop results can be seen in the photos. I needed to drill two additional bolt holes in the disk, enlarge two of the existing bolt holes, and buy four longer disk mounting bolts.

    After getting the disk mounted on the wheel and the wheel back on the bike I setup the stock GS caliper on the disk at what I thought was a good position. I then used some thick card stock to make a caliper adapter template and then transferred that to a piece of aluminum flat stock with a permanent marking pen. Using just a hacksaw, file and hand drill, I could in short time have the adapter in the photos. I later bought a late model four piston BMW caliper, and that took very little time to adapt, but I would say the stock GS caliper gave sufficient performance, and seemed to have less drag. I've been thinking to re-try the old caliper again.

    The caliper should be somewhat centered on the disk, otherwise new pads may not fit on the narrow side. I did my alignment by applying the brake to hold the caliper in position without the mounting bolts and then fitting some spacers of large nuts and washers of sufficient thickness so that they just slipped into position. The spacers I used can be seen in the photo of the back of the caliper.

    At first I used the stock brake line with the stock caliper, but then I upgraded to a braided stainless line. I noticed a stiffer brake lever, and in general what I thought was a better brake feel. To make the line I bought some bulk Earl's Speed Flex -3 hose and the appropriate reusable hose ends. I found the stuff easy enough to work with. I bought some spare hose and olives so I can make future repairs. I found the olives are not reusable. I also carry a few olives in my tool kit when I go on tour, just in case. The hose comes either with or without a plastic covering. I read somewhere that dirt gets inside the braid of the uncoated hose and can cause premature wear, so I got the clear coated type. I think it looks better than the bare. I also put some heat-shrink tubing on the hose ends as seen in the photos to seal out grit. Here is a link to the speed-flex catalog:

    http://www.holley.com/data/Catalogs/Brake Systems.pdf

    I found the Earl's on-line supplier Fluid Systems Engineering (http://www.fluidsystemseng.com) and received very good service from them. Here is what I bought:

    Code:
      600031 speed-flex -3 clear coat bulk hose
      600893 speed-seal -3 30 deg non-adjustable
      600593 speed-seal -3 30 deg adjustable
      699030 speed-seal -3 spare olives
    
    The photos show the finish brake line after some use.

    I now have about 30,000 miles on the big disk, and haven't had any real problems. The disk center carrier is made of aluminum, and is easier to bend than the original BMW disk. One time while in Mexico I had a tire patch installed and I noticed afterword that there was a lot of disk run-out. He must have bent the carrier while working on the wheel. I straightened it out by carefully hitting the center carrier with a few blocks of wood as I checked the run-out by how much drag there was. When at home I have a dial indicator I sometimes use to check or adjust the run-out. There are cheaper versions of the snowflake disk the have a steel center carrier, and I've thought that one of those might have been a good choice for its durability.

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/01-new-disk-package.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/01-new-disk-package-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/01-new-disk-package.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/02-disk-adapter-drawing.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/02-disk-adapter-drawing-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/02-disk-adapter-drawing.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/03-disk-adapter-inside.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/03-disk-adapter-inside-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/03-disk-adapter-inside.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/04-disk-adapter-outside.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/04-disk-adapter-outside-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/04-disk-adapter-outside.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/05-new-disk-mounted.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/05-new-disk-mounted-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/05-new-disk-mounted.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/06-side-view-disk.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/06-side-view-disk-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/06-side-view-disk.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/07-two-piston-adapter.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/07-two-piston-adapter-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/07-two-piston-adapter.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/08-two-piston-installed.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/08-two-piston-installed-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/08-two-piston-installed.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/09-four-piston-adapter.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/09-four-piston-adapter-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/09-four-piston-adapter.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/10-four-piston-adapter-fab.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/10-four-piston-adapter-fab-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/10-four-piston-adapter-fab.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/11-four-piston-adapter-installed.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/11-four-piston-adapter-installed-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/11-four-piston-adapter-installed.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/12-caliper-spacers.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/12-caliper-spacers-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/12-caliper-spacers.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/13-hose-parts.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/13-hose-parts-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/13-hose-parts.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/14-hose-end-upper.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/14-hose-end-upper-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/14-hose-end-upper.jpg"></a>

    <a href="http://stuff.gotdns.org/bike/pd-front-brake/15-hose-end-lower.jpg" target="_blank"><img src="http://stuff.gotdns.org/bike/pd-front-brake/15-hose-end-lower-sm.jpg" border="0" alt="http://stuff.gotdns.org/bike/pd-front-brake/15-hose-end-lower.jpg"></a>

    -x3300
  15. soyanarchisto

    soyanarchisto Long timer

    Joined:
    Sep 1, 2005
    Oddometer:
    4,427
    Location:
    Sunny PDX
  16. lesman

    lesman Live easy, Brake Hard

    Joined:
    Sep 7, 2006
    Oddometer:
    2,368
    Location:
    Houston, Texas
    I looked at the Ducati Rotor setup pictures.....wow







    Les
  17. HPMGuy

    HPMGuy Been here awhile

    Joined:
    Mar 17, 2006
    Oddometer:
    265
    Location:
    Mid-California
    I received the adapters back from anodize yesterday, and they would be ready to ship if the vendor hadn't mixed up the bolt order. I should have the correct bolts sometime next week.

    [​IMG]
  18. soyanarchisto

    soyanarchisto Long timer

    Joined:
    Sep 1, 2005
    Oddometer:
    4,427
    Location:
    Sunny PDX
    I am still on the list for one set.
  19. deadbird

    deadbird Very Large Bird

    Joined:
    Jun 14, 2002
    Oddometer:
    153
    Location:
    santa cruz,ca
    Those look so SWEET!
    Got my caliper, Nissin 4 pot.
    Better get my brake line made up this next week.
    Looking forward to better stopping.
    Is it time to send the $ yet?
    -Deadbird
  20. Renegade6

    Renegade6 Been here awhile

    Joined:
    Feb 23, 2004
    Oddometer:
    820
    Location:
    Ft. Riley, KS
    HPM Guy, any updates?