First, thanks to Gary in CA for sharing his brake upgrade experience, thanks to Slybones for sharing his experience through his excellent website of Connie information, and thanks to COGger zrxmopar (Shaun) for his original 4-pot brake brackets which, based on Slybones' brake upgrade webpage, I’ve probably copied.

My bike is an '04 model.  The calipers are 4-pot Suzuki GSXR 750, 2001 to 2003 model, fresh seal kit installed.  The rotors are EBC 320mm Contour.  The pads are EBC HH.  The Galfer brake lines have been on my bike for years with the OEM calipers, not changed for this upgrade.

I started by making a full-size prototype out of Plexiglas sheet to get the locations for the holes and the shape to fit the calipers.  It took 2 trials to get the calipers perfectly aligned for the pads to track correctly on the 320mm rotors.  The prototype proved that the flat plate centers the caliper perfectly on the rotor when used on the inside face of the caliper lugs.  The bracket is tapped for the 4 bolts, the threads in the caliper lugs are drilled out to pass the M8x1.25x16 flange head bolts.  No other modification to the calipers at all.  The OEM C10 brake bolts are used at the fork leg.

The pics tell the story … the brackets are 3/16” steel plate.  Holes were done with a benchtop drill press through the Plexiglas template and hand-tapped.  I was not able to get time on a mill as I’d hoped when I started this project, so finally I just carved the brackets using abrasive cutoff and grinding disks on a 4.5 in Bosch angle grinder – very easy and quick.  A few licks with a file to round the sharp edges and a couple of coats of rattle-can caliper paint on the brackets to finish.


View of the bracket from the wheel-side shows the basic shape



Close-up from the outside; flange head bolts through the calipers are zinc plate, class 10.9





Looks like I'll have to watch that speedo cable to ensure it doesn't hang on the corner of the caliper

Very clever and "clear" idea to use the plexiglas to make your prototypes..... Looking good!

Plexiglas drills and taps easy, allowing a full bolt-up fit and alignment test.

Very nice This might be my next project.

Jack

How much better is the braking with these calipers?

How much better is the braking with these calipers?

The braking improves by a factor of  'Blah!' to 'WOW! ' 
 It is not just the calipers, it is the calipers and going from 300mm to 320mm.

Sweet, is there anyone making the adapter plates yet or is this a figure it out yourself deal?

Sweet, is there anyone making the adapter plates yet or is this a figure it out yourself deal?

We are still working on it. 

4 pot calipers? 320mm discs? It doesn't get any better than this! Nice job! 

I want these plates in the worst way.

It's about time someone made a neat & simple bracket for this. Very similar to the ones I make for the 86-93 models. Well done!

Regards, Russell

We are still working on it.

 

I'm certain you can sell a ton of them...in fact, if there's a waiting list, put me on it!      

So I am looking for info on the 4 pot mod to the older Connies. Cost? Parts needed? Thanks

Here's what I did. http://forum.cog-online.org/index.php/topic,28138.0.html You can see em in Vermont in a few days if you are going.

Here's what I did. http://forum.cog-online.org/index.php/topic,28138.0.html You can see em in Vermont in a few days if you are going.

Very nice 2F. Where did you get the rotors and what brand are they? I am fixing to fabricate some of these brackets very soon, as soon as the temperature gets below 100 here in Texas, which should be about november.

Jim,
The rotors are Chinese from these guys http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681 and are made for a Yamaha YZF R7. They fit the older model center hole, but the mounting holes need to be drilled out one size.  I don't have many miles on them yet, but by the time I get back from Vermont they will be fully tested.

Jim,
The rotors are Chinese from these guys http://cgi.ebay.com/ebaymotors/ws/eBayISAPI.dll?ViewItem&item=310261175803#ht_1077wt_681 and are made for a Yamaha YZF R7. They fit the older model center hole, but the mounting holes need to be drilled out one size.  I don't have many miles on them yet, but by the time I get back from Vermont they will be fully tested.

So they will only fit the older model front wheel ?

Yes, but I would be surprised if they don't make em for the new style.

edit to add:

http://cgi.ebay.com/Front-Brake-Disc-Kawasaki-ZG1000-ConCours-94-06-/250612779613?pt=UK_Motorcycle_Parts&hash=item3a59af8a5d#ht_1359wt_952

Brian / Jim - I notice that the rotors you linked above are replacement for the 94-06 Connie, so they are 300mm, not 320mm.

If you want 320mm for exact fit on the 94-06 Connie, look for replacements for the following bikes (among others) which came with 320mm stock and the correct bolt pattern / offset:

93-01 ZX11
00-03 ZX12