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Yamaha XS750 Brake Rebuild

This is a discussion on Yamaha XS750 Brake Rebuild within the Technical forums, part of the Caferacer.net Forums category; Originally Posted by Integra99 Cool cheers, did you use the rear peg brackets or did you fabricate a tab onto the frame from memory? The ...

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Thread: Yamaha XS750 Brake Rebuild

  1. #11
    Senior Member steveo's Avatar
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    Quote Originally Posted by Integra99 View Post
    Cool cheers, did you use the rear peg brackets or did you fabricate a tab onto the frame from memory?
    The Raask rearsets bolted straight on, no need to fabricate anything.
    "You were only supposed to blow the bloody doors off"

  2. #12
    Senior Member Integra99's Avatar
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    Hopefully the image comes out... the idiot I bought the bike from had cut the rear peg mounts..

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  3. #13
    Junior Member FranklinMarquette's Avatar
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    Okay so I did some adding up and found that it would be about $400 to refurbish the front calipers ($200) and put race tech emulators in the forks ($200). Now the forks look really good so they probably don't need anything ... I could for now just put them back on so I can get the bike running sooner.

    Or ... I can buy an entire front end for a 08-16 R6 for around $850 on eBay. That includes the MC, switches, throttle, forks, calipers, levers, triple trees, and clip ons. Is the R6 suspension longer, shorter, or the same as the XS750? Does the R6 rotor fit the XS750 bolt pattern? I've found many XS750 builds just using the rebuilt stock setup but by the time i'm done rebuilding and buying the extra stuff that a R6 front end would include its going to be close to the same price. I've found many R1 front ends as well ... they look similar what's the difference? Found a set of used FZR600 rotors on eBay for $60 ... is it okay to buy used or is there a better new option out there?

    Also i'd like to put on a XS400 wheel but the XS400 only had a single front disk. How would I mount dual FZR disks on it? I've seen some builds that have done it so it is possible.

    R6 front end:

    http://www.ebay.com/itm/08-16-YAMAHA...3D262916873748

    FZR600 rotors:

    http://www.ebay.com/itm/Yamaha-FZR-6...wAAOSw9GhYm4mv

    XS400 wheel:

    http://www.ebay.com/itm/1981-Yamaha-...-/232288847341
    Last edited by FranklinMarquette; 04-18-2017 at 10:50 AM.

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  5. #14
    jcw
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    Senior Member jcw's Avatar
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    Quote Originally Posted by FranklinMarquette View Post
    Okay so I did some adding up and found that it would be about $400 to refurbish the front calipers ($200) and put race tech emulators in the forks ($200). Now the forks look really good so they probably don't need anything ... I could for now just put them back on so I can get the bike running sooner.

    Or ... I can buy an entire front end for a 08-16 R6 for around $850 on eBay. That includes the MC, switches, throttle, forks, calipers, levers, triple trees, and clip ons. Is the R6 suspension longer, shorter, or the same as the XS750? Does the R6 rotor fit the XS750 bolt pattern? I've found many XS750 builds just using the rebuilt stock setup but by the time i'm done rebuilding and buying the extra stuff that a R6 front end would include its going to be close to the same price. I've found many R1 front ends as well ... they look similar what's the difference? Found a set of used FZR600 rotors on eBay for $60 ... is it okay to buy used or is there a better new option out there?

    Also i'd like to put on a XS400 wheel but the XS400 only had a single front disk. How would I mount dual FZR disks on it? I've seen some builds that have done it so it is possible.

    R6 front end:

    08-16 YAMAHA R6 FRONT END FORKS SUSPENSION HANDLEBARS TRIPLE TREE COMPLETE

    FZR600 rotors:

    Yamaha FZR 600 Front Brake Rotors | eBay

    XS400 wheel:

    1981 Yamaha XS400 XS650 XS 400 Y622' front wheel rim 18in | eBay

    If you use a different bike front end, you will either have mismatched wheels or have to machine custom spacers (center and both sides) and different bearings for the new front axle with the old wheel. Then you have to match the bolt pattern (R1/R6 rotors do not match the xs750 wheel). Machine spacers to move the rotors out. If you use a set up with radial brakes, the spacers are going to be about 1 - 1 1/2" wide on each side. If they are axial brakes you can split the difference between caliper spacers and rotor spacers.

    The XS400 wheel is problematic more than just the lack of the rotors on one side. First issue is tube or tubeless. The early ones were meant for tubes and tires. the later ones tubeless. Second problem is the bearings for the XS400 were even smaller than the xs750/850. So while you can get different bearings to fit a bigger modern axle on the xs750/850. No such bearings exist to convert the xs400 wheel. So that means having the wheel machined to fit a bigger bearing. Finally, while you are at it, you could throw some more money at it and have the wheel machined for rotors on the opposite side.

    If the above doesn't make sense, it will when you start in on the project.

    If you think $400 is a lot? The path you are suggesting will be much much much more expensive and time consuming.


    Totally not saying it can't be done. It can (I've done it). But if this is your first bike, my question is WHY?!?!?!?!?



    Forks might look good, but they could be filled with mud on bikes this old.
    Last edited by jcw; 04-18-2017 at 11:48 AM.

  6. #15
    Senior Member 8ball's Avatar
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    Quote Originally Posted by FranklinMarquette View Post
    Okay so I did some adding up and found that it would be about $400 to refurbish the front calipers ($200) and put race tech emulators in the forks ($200). Now the forks look really good so they probably don't need anything ... I could for now just put them back on so I can get the bike running sooner.

    Or ... I can buy an entire front end for a 08-16 R6 for around $850 on eBay. That includes the MC, switches, throttle, forks, calipers, levers, triple trees, and clip ons. Is the R6 suspension longer, shorter, or the same as the XS750? Does the R6 rotor fit the XS750 bolt pattern? I've found many XS750 builds just using the rebuilt stock setup but by the time i'm done rebuilding and buying the extra stuff that a R6 front end would include its going to be close to the same price. I've found many R1 front ends as well ... they look similar what's the difference? Found a set of used FZR600 rotors on eBay for $60 ... is it okay to buy used or is there a better new option out there?

    Also i'd like to put on a XS400 wheel but the XS400 only had a single front disk. How would I mount dual FZR disks on it? I've seen some builds that have done it so it is possible.

    R6 front end:

    08-16 YAMAHA R6 FRONT END FORKS SUSPENSION HANDLEBARS TRIPLE TREE COMPLETE | eBay

    FZR600 rotors:

    Yamaha FZR 600 Front Brake Rotors | eBay

    XS400 wheel:

    1981 Yamaha XS400 XS650 XS 400 Y622' front wheel rim 18in | eBay

    You won't even come close to being done by just bolting up those parts. The 06 and up R6 forks are made for much larger rotors than the FZR rotors. The rotor offset will be all wrong because the forks are made for a much wider wheel. Since the calipers on that front end are radial mount, the offset can't be altered....not easily. The forks are much shorter than the XS forks, and the are made for an entirely different head stock angle so your trail measurements will be altered drastically....particularly if you intend to use a large diameter wheel.

    And just for information, the calipers that Integra has pictured on his bike are NOT from a 2005. They are from an 03-04 R6, or an 06-09 R6S. The 05 and up R6 had radial mount calipers.
    I always find a soap box useful to get on my high horse.

    Quote Originally Posted by roccitycafe View Post
    .... same thing with furniture, it doesn't have to be straight or not wobble, or keep thing from rolling off it, or not collapse when sat upon, it's personal taste man... if I want a dining room set that endangers the life of my dinner party guests, then it doesn't need second hand approval

    My GS550 Build Thread

  7. #16
    Junior Member FranklinMarquette's Avatar
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    The only reason I say the forks are most likely okay is because the old man rebuilt them right before he parked it for ten years. My original plan was to simply rebuild the stock forks and calipers but I just want to make sure that the bike performs well. I'm not looking for race level performance ... just a braking system that slows me down and a suspension system that makes the bumps more tolerable. I'm just trying to make a rideable bike out of the old girl. If a rebuilt stock system will do that then that is what I will do. I suppose I just need to get the bike running and then perhaps in the future i'll do some more complex stuff if I'm not happy.

    The bike is completely stripped I just need to pick a seat and order a tank (the one I have is the bulbous one off the Special) and then modify the frame.

    For now I'm just going the more simpler route ... I'd rather do a simple modest build correctly than try and fail to build a complex one.

    Thanks everyone for the advice! As soon as I start building I'll post pictures

  8. #17
    Senior Member 8ball's Avatar
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    I'm not sure why people say $100 for caliper rebuilds. Do it yourself. Just disassemble them and clean 'em up. Use some compressed air to pop the pistons out (make sure to us a rag to catch the piston). As long as they are not scored or pitted badly they can be re-used. Even some pitting can be cleaned up with some fine emory cloth. A seal kit is $25 per side, and this shouldn't be a hard to find item since Yamaha had many calipers that were common. Use a light coating of grease an re-assemble. Won't even take you all afternoon.
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    Last edited by 8ball; 04-18-2017 at 05:40 PM.
    I always find a soap box useful to get on my high horse.

    Quote Originally Posted by roccitycafe View Post
    .... same thing with furniture, it doesn't have to be straight or not wobble, or keep thing from rolling off it, or not collapse when sat upon, it's personal taste man... if I want a dining room set that endangers the life of my dinner party guests, then it doesn't need second hand approval

    My GS550 Build Thread

  9. #18
    Senior Member Integra99's Avatar
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    Quote Originally Posted by 8ball View Post
    You won't even come close to being done by just bolting up those parts. The 06 and up R6 forks are made for much larger rotors than the FZR rotors. The rotor offset will be all wrong because the forks are made for a much wider wheel. Since the calipers on that front end are radial mount, the offset can't be altered....not easily. The forks are much shorter than the XS forks, and the are made for an entirely different head stock angle so your trail measurements will be altered drastically....particularly if you intend to use a large diameter wheel.

    And just for information, the calipers that Integra has pictured on his bike are NOT from a 2005. They are from an 03-04 R6, or an 06-09 R6S. The 05 and up R6 had radial mount calipers.
    "Actually 8ball in the UK early 2005 R6 SL used standard mount calipers, we did not see radial calipers until late 2005/06 so most 2005 UK models run std calipers and no upside dowe forks. I should know I had two and these are from one of them"!

  10. #19
    Senior Member 8ball's Avatar
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    Regardless of how the U.K. registered bikes, Yamaha considered the 2005 model the R6T. It was a bastard year for the bike. It was much more than just USD forks. The forks rotors and triple treewere 1 year only versions. It looked like other 2nd gen R6's, but, the Frame was different, the radiator was different, the lower fairings were slightly different, shock length was different, ride height was different, throttle bodies were different. I only brought it up because for just about the entire world, if someone orders parts for a 2005 and expects parts to interchange with 2004 R6 parts, they will be disappointed.

    i don't know if the U.K. Uses a 17 digit VIN, but if so, I'd be curious what the 10th digit would be on those 2005 bikes with standard forks.
    I always find a soap box useful to get on my high horse.

    Quote Originally Posted by roccitycafe View Post
    .... same thing with furniture, it doesn't have to be straight or not wobble, or keep thing from rolling off it, or not collapse when sat upon, it's personal taste man... if I want a dining room set that endangers the life of my dinner party guests, then it doesn't need second hand approval

    My GS550 Build Thread

  11. #20
    Senior Member Integra99's Avatar
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    In truth I'm no expert but I did own a UK 2005 R6 - just like this advertised.. hence my calipers are 2005 ones according to how the registration works here... an example of a 2005 SL model as proof... Yamaha YZF R6 5SL 2005 *Very Good Condition* | eBay - registered in 2005! I think it was the 2nd half of our registration year in September when they had the revised R6 to the newer version, I actually wanted that model"!

    Either way its irrelevant now as the OP is keeping a standard set up... and I have a GSXR 600 lol... but it caused issues in the UK too with the overlap!!

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