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[Lipo423]

Hello all,

As I mentioned last week in a different thread I'm making a front braking upgrade. As a few of you pointed out the front brake system in our S models is "nothing to write home about" so I have decided to improve it myself.
I apologize for the technical words. It is very difficult for me to explain/describe the process in proper English. Sorry about that 

Current front brake-system weaknesses

- Stopping power is available at a very high lever pressure, confidence is limited...
- Brake lever has no adjustment (if you have a small hand...)
- Brake pads -although sintered- have a very small contact section on the disk and need a long break-in process.
- Disk quality
- Brake calliper & pump have limited power (low cost design)
- Brake calliper + pads have an annoying flexion/noise (a kind of "clock, clock) because of its original design which makes riding unpleasant.

Components Cost

- Brembo 16X18 Radial pump 190 Euros (long lever + brake switch)
- Brembo 4 piston Axial calliper 248 Euros
- Custom made 320mm disk 265 Euros
- Front suspension new spring + tuning 175 Euros
- Brake calliper bracket/support (around 200-250 Euros)
TOTAL    1.100 Euros aprox.

Challenges

- Will not change the front suspension to keep budget within reasonable (although it would allow us to install Radial callipers) -cost would be 3X of original budget-
- Front suspension has a "soft" feeling, will have to change the spring, oil, and settings.
- The new Brembo axial calliper will require a customized "bracket" or support to hold it properly/safely to the fork
- Almost custom made disk will be needed

This is a basic components picture (bracket/support not included -it will be made tomorrow!)


I will give you further details in the next thread (installation/mounting, achieved improvements)

[protomech]

An expensive upgrade. The new rotor is pretty massive : )

Looking forward to seeing how it turns out.

[Lipo423]

Agreed...that's what you pay for safety  the rotor seems bigger because of the picture (it is only 10mm bigger than the original one)

[CliC]

Cool. Not sure I'd spend 1100 euros (or even USD) on something like this for mine, as stock is good enough, but I'll be interested to see how it works out.

Re: custom 320 mm radial rotor: didn't Buell sportbikes use that size? Maybe not an option in Europe but something that might be taken advantage of in the US.

[Lipo423]

There are a few bike brands using this size...the problem comes out with the bike rim, so you need to mix different components (which I do not know the name in English) to get a full disk rotor that fits the rim.
Yes, I agree the price tag is high (you are actually getting a 100% new braking system)..."my problem" is that I'm used to better performing brakes & I hate the braking noise you get with the std. system (the "clock, clock")

[manlytom]

Hi Lipo
Did u look at all going to the wreckers and get a complete replacment front end? From a suitable super moto?
Might be less hassle. Or is it hard to find suitable ones?

[Lipo423]

Thanks for your suggestion Tom.
Unfortunately none of the components are std. (I mean, what you can get easily to be installed in a regular roadbike fork/wheel).
The very big deal is the brake calliper bracket/support, which has to be specially made/machined for the fork. At the moment evaluating if it is going to be Aluminium or steel...

[Larry295]

But what's the point in upgrading the brakes, when the whole purpose of this bike is to be efficient, and therefore maximize the regen??
I am actually trying to NOT use the brakes at all if I can avoid it. I most slow down with the regen...

[CliC]

If you ride aggressively or sportingly, regen braking is probably furthest from your mind . The primary purpose of the bike for me is fun; the electric part is gravy.

But I try to maximize my regen as you do. Not having to downshift to get engine braking is cool.

Fortunately my brakes don't (yet) make a "clock clock" noise, the lever is not 1-finger but is comfortable for me, and I've had to haul her down in a hurry a couple times already and didn't feel it wasn't going to stop. (Now the fact that I didn't anticipate those situations is something I will be working on :/ )

[Larry295]

Gotcha!! Well to each its own.
I ride my Street Triple or 150hp Multistrada aggressively. but with 15hp on tap, I don't see how this bike could be even remotely aggressive...

[Lipo423]

Follow me in a very twisty road...you will understand what having a mediocre braking system means  Just kidding...

This is not an sports bike, but you can go relatevily fast in those roads if you want to have some fun (which I do)...but this is not the entirely point, the point is that  having had a few bikes in my life I just do not like the S ZF# braking system...

[BSDThw]

Hi Lipo423,

nice job, I do like modifications, OK the brake wouldn't be necessary for me, I don't ride so hard.

But I just read the Zero Recall paper and there is a line that roughly translated says if you have repaired your front brake (switch) already you may get money back.

Now you just have to convince Zero that your mod was necessary to fix this problem ,

¡Sólo estoy bromeando!

maybe you will become the first here having more tier and wear at the front tire as at the rear

[Lipo423]

Mmmm...I haven´t taken into account the front tire business...the good news is that is cheaper than the rear one  ...

Finally, and in order to increase stifness/safety factor, we have decided to make the caliper bracket/support of steel -more expensive

More info the next week...

Vielen dank!!!!

[Le Z Turbo]

Hi, the thread is old now but I have questions to apply them to my 2013 DS.

About the fork new springs: were they customly made for the fork ? And what about tuning: was it a thicker oil change or revalving of the piston ?

Have a good week end
Laurent