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Can you fix warped brake rotor.

This is a discussion on Can you fix warped brake rotor. within the ZR-7 Maintenance forums, part of the Kawasaki ZR-7 category; I have a warped front brake rotor and it's getting worse. The calipers are regularly maintained and I'm not sure how it warped. Maybe the ...

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  1. #1
    Rising Star dkawa's Avatar
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    Question Can you fix warped brake rotor.

    I have a warped front brake rotor and it's getting worse. The calipers are regularly maintained and I'm not sure how it warped. Maybe the construction road accident I had last year in mud? Can these be fixed like you can do on car rotors or what is the best after market solution without costing major money?
    Dan Meldrum
    Airdrie, Alberta. Canada

    2008 DL 650 ABS
    2002 ZR7S
    Jardine RT One Street slip on, Ivans jet kit, Corbin seat, Kawasaki Engine Guards, fuel gauge mod, 12v accessory socket, C & G Mirror Extenders, Eastern Beaver headlight relays, Galfer braided brake lines.

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  3. #2
    Rising Star Cracker Jack's Avatar
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    I believe I read in the factory manual that they are too thin to be repaired. It may have been for another Kawasaki I have, and in a Clymer or Hanes manual, but nevertheless that seems to be the consensus. Does anyone know different?


    Jack
    Cracker Jack

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  4. #3
    Silver Member Serpentine's Avatar
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    Nope it's trash, too thin to be turned and can not be straightened.
    Can't slow down, the Langoliers will get me

  5. #4
    Timex dklay's Avatar
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    several years ago I spoke with a guy who does disc brake machining at a local machine shop about re-surfacing the discs for another bike I had (the discs were thicker than the ZR-7). He said that basically ALL motorcycle discs were too thin to be machined safely without the heat warping them further.

  6. #5
    williamr
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    The only thing I'd add is get a dial guage on the rotor to make sure that it is a warped rotor and not any other problem. Then buy a new one.

    Rob

  7. #6
    Rising Star dkawa's Avatar
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    I don't even need to use a dial gauge on the rotors. It's very clear that there is a high spot on both of them. Why would this happen? The calipers were always lubed and the pistons were cleaned as regular maintenance. Just bad luck?
    Dan Meldrum
    Airdrie, Alberta. Canada

    2008 DL 650 ABS
    2002 ZR7S
    Jardine RT One Street slip on, Ivans jet kit, Corbin seat, Kawasaki Engine Guards, fuel gauge mod, 12v accessory socket, C & G Mirror Extenders, Eastern Beaver headlight relays, Galfer braided brake lines.

  8. #7
    Maintenance Overlord graeme gould's Avatar
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    Hi Dkawa,

    Two reasons are:

    1/ Mechanical knock/bump

    2/ Hot disc spashed with water, that is local rapid cooling and distortion.

    OK down to the dealer and pick up a pair of discs, also you might as well do a brake fluid change, some would change the pads as well for a fresh start. gg would stay with the old pads if they are in reasonable condition.

    gg@bb, ava good day

    gg@bb,ava good day
    Graeme Gould at Byron Bay the most Easterly part of Australia

  9. #8
    Rising Star dkawa's Avatar
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    Thanks GG, that's the only thing I could think of causing the problem. I've heard of some people in the past with floating rotors having one of the floating spots getting seized or stuck. I looked at that and all is good. The calipers slides were always lubed and I've cleaned the pistons with an old tooth brush and some brake clean in the past also. This is just to get rid of the ring of crude that builds up on the piston. The pistons seem to be okay. I know when they have been seated for awhile just like on car it takes a bit of force to push them in, but they are moving fine by hand once this is done. I know I have been riding in the past and have hit rain on more them one occasion. Also had a drop with the bike on a muddy construction road beginning of this season. I think I will see if I can get a better deal on EBC rotors over OEM and yes, I'm changing the pads & brake fluid flush. I may end my riding season early this year as I'm short on funds to do this right now and also too busy with other things. A high speed panic stop could be disastrous with the way the brakes are now. I was going to look into kevlar pads that I think are not as hard on the rotor.

    I almost forgot, I gave my front tire to the dealer to put on my new tire. I was careful with the rim trying not to put any pressure on the rotors. I had the tire on some 2 x 4 pieces of wood in the trunk of the car. Not sure if something could have happened when the rim was out of my control.
    Last edited by dkawa; 09-28-08 at 12:15 PM. Reason: Adding note:
    Dan Meldrum
    Airdrie, Alberta. Canada

    2008 DL 650 ABS
    2002 ZR7S
    Jardine RT One Street slip on, Ivans jet kit, Corbin seat, Kawasaki Engine Guards, fuel gauge mod, 12v accessory socket, C & G Mirror Extenders, Eastern Beaver headlight relays, Galfer braided brake lines.

  10. #9
    Rising Star dkawa's Avatar
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    Ok, so I have a set of EBC Pro-lite rotors on the way. I'm changing the pads to EBC double - H pads. They are supposed to be good pads without being to hard on the rotors. I could have used my old OEM pads, but looking at the rotors I think they are very hard on them. They last a long time, but groove the &T%^% out the rotors. I'm also going to the Kawa dealer to buy new lower pins for the pads on the caliper. I find it stupid that the manufacture of the calipers made the bottom support pin out of material softer then the brake pad that it supports. They eventually were a groove into the pin and cause the pad to possibly hang up from time to time. Going all out on this as rotors are worth $500. bucks. OEM Kawasaki are even more.
    http://www.ebcbrakes.com/motorcycle.html
    Dan Meldrum
    Airdrie, Alberta. Canada

    2008 DL 650 ABS
    2002 ZR7S
    Jardine RT One Street slip on, Ivans jet kit, Corbin seat, Kawasaki Engine Guards, fuel gauge mod, 12v accessory socket, C & G Mirror Extenders, Eastern Beaver headlight relays, Galfer braided brake lines.

  11. #10
    Rising Star Cracker Jack's Avatar
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    There are far worse places to spend $500, most of them being in Nevada. I too, am considering this upgrade along with some others.

    Jack
    Cracker Jack

    74 Norton
    02 ZG1000
    03 ZR-7s (hers)
    03 ZR-7s (mine)

    83 GS750 (sold)
    04 GS500F (sold)
    97 ZL600 (sold)
    75 Norton Interstate (sold)
    71 Norton Roadster (sold)

  12. #11
    Rising Star dkawa's Avatar
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    I installed the new rotors and pads. I know they need to seat in and they recommend urban use with light braking to seat the pads and rotors. I did a full brake maintenance cleaned pistons, lubed sliders, etc... I know the pistons need to settle in after being pushed back all the way in, but how much drag is supposed to be on the new rotors and pads. Seems like they are very noisy and lever feels spongy like when you have air in the system.. I heard the EBC HH pads apparently have a little more drag noise from other site posts. Is it normal with all new stuff up front for the brakes to sound like there dragging until seated in?
    Last edited by dkawa; 10-12-08 at 10:10 AM. Reason: Forgot to add note.
    Dan Meldrum
    Airdrie, Alberta. Canada

    2008 DL 650 ABS
    2002 ZR7S
    Jardine RT One Street slip on, Ivans jet kit, Corbin seat, Kawasaki Engine Guards, fuel gauge mod, 12v accessory socket, C & G Mirror Extenders, Eastern Beaver headlight relays, Galfer braided brake lines.

  13. #12
    Supreme Being Craig Jackman's Avatar
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    Yup.
    Craig Jackman - '03 Suzuki DL1000 V-Strom - "The Vee"

    '02 ZR-7S "The Silver Seven" (note - obscure hockey reference) - SOLD MAY 2010

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