A possible alternative cause of warped discs

[Martin#30]

I have been giving my calipers a long overdue inspection and clean today.

12,000 miles of accumulated brake dust and road crud meant that a pair of pads on each caliper were stuck fast, and had to be quite forcibly levered out with a screwdriver. The other two were free to simply fall out, as I would expect when the pad retaining pins were removed.

These pair of stuck pads mean they will not be retracting away from the disk anywhere near as easily as they should, and I would not be at all surprised to know that this is the root cause of the warping discs.

I will be removing pads and thoroughly cleaning the calipers every 4k miles from now on. My bike has been main dealer serviced all its life, but it is obvious that the dealer does not do this task as part of the service, nor when they replaced the pads at 12k in my opinion. For those that know my genetic pre-disposition to sponge-dodging, this could perhaps be seen as a recommendation to do the same.

Martin.

[Lonewolf]

So far I've always serviced the GTR myself however with the new GTR I'll be getting it dealer serviced but I'll continue to do some additional work myself. Dealers dont tend to put any TLC into the service and dont generally do such work as checking/cleaning the callipers which I think should be doe routinely by them but never is.

[Rusty]

When I have time ....( when on earth is that going to be ? ) I need to go and do a weeks "Bike Mechanics " refresher course ! I did one MANY years ago when the latest bike on the stand was a Honda 250 or 400 Super Dream ... .don't have the tools and the know how ... but doing all this minor stuff is exactly what I would like to be able to do .. pads oils and filters wheels off splines etc ..... one day !

[Lonewolf]

To be honest Rusty the GTR is a pretty easy bike to work on. Simple tasks like changing brake, clutch fluid etc, brake pads, air filter, oil, oil filter, final drive oil, coolant, greasing brake levers/pedals etc its reasonably easy to do and having done it a few times now  it doesnt take me that long.

[Kwikasfuki]

Before the GTR the last time I picked up tools was working on my Ford Cortina way back in the 80s. Having witnessed some of the shambles so called dealers made with my other bikes, I decided that the GTR would get my personal attention. As you can see from the various threads on this forum, I pretty much do everything on the GTR. I wouldn't say its cheap because the initial outlay can be high simply because you need to build up a portfolio of decent tools.

You also have to put up with the moaning from the missus. Take for example the bearing I recently changed. She commented that it would have been cheaper for a garage to do it. Maybe. But now I know how to do them properly, its gives me a sense of satisfaction and next time I'll do them even quicker. Same with the brakes, removing the wheels, greasing splines ...

There is a set of videos available from the states that cover the majority of servicing items. There's also the servicing manual available (if you know where to obtain it from - ahem).

Besides, I enjoy working on the bike. It's therapeutic. There's many people on this forum that know a lot more about bikes than me. Doesn't prevent me from tinkering!

[Boomer]

Whenever I change the front tyre or the front brake pads I have cleaned the calipers and pistons.
It only takes a few minutes.
I also hose down the "buttons" that hold the disc to the carrier with Brake Cleaner and make sure that they can move.
Never had a warped disc and still on the originals @ 48.5k miles.

[Martin#30]

Never had a warped disc and still on the originals @ 48.5k miles.

Boomer,

Have you measured the thickness of the discs on yours? Reason I ask is that 48.5k miles astounds me. The discs on my 2010 24,000 miler are down at 4.43mm, i.e. worn below their 4.5mm recommended thickness.

In that time, I have had one set of new pads at 12k and these will be due for replacement in the next 2,000 miles.

Martin.

[Hans]

I had both front brake discs and calipers has been replaced (under warranty) on my 2010 model. (16.000km) My dealer was at a Kawasaki course in Holland, where he discussed this with Kawasaki. They confirmed that there have been several cases (in Europe) where "warped discs" occurred. As an experiment, my dealer was allowed to replace both discs and calipers with a set from the new ZZR1400 (2012 model). I can not notice any difference - besides the brakes work!

[barnyardsavage]

i got told by my local dealer the later discs had the centre black support area strenghtened

[viper]

Whenever I change the front tyre or the front brake pads I have cleaned the calipers and pistons.
It only takes a few minutes.
I also hose down the "buttons" that hold the disc to the carrier with Brake Cleaner and make sure that they can move.
Never had a warped disc and still on the originals @ 48.5k miles.

disc buttons , yes well prompted , free those buttons , do they spin

[O.C.]

very good point...bobbins should spin  , and I guess that for a reason.

[Nok12rs]

Problematic high maintenance discs and pads and callipers.............is this normal?  Maybe my ignorance was bliss, but I never had an issue.  (scatch head emoticom please).

Now I worry But then I am shortlisted to worry for England 2012.