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77 xs650 Dual Disc upgrade

Discussion in 'The Garage' started by vtwinsrgood, Apr 17, 2019 at 12:42 PM.

  1. vtwinsrgood

    vtwinsrgood XS650 Member

    Morning/Afternoon All, :p
    I ordered up new left/right caliper's and the disc rotors/pads.
    In my lack of thinking things through, I didn't order the front brake hose manifold as there will be two discs not one.. Doh!!
    Is there anything else I am needing? I am ordering via xs650direct in Canada. Has anyone here ordered through them, or done the same conversion/upgrade?
    Thanks in advance!
    VTRG
     
  2. 5twins

    5twins XS650 Guru Top Contributor

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    Usually, these bikes come stock with that "manifold" or line splitter. It's usually mounted on the lower triple tree.
     
  3. vtwinsrgood

    vtwinsrgood XS650 Member

    ahhh, I see now. Looks like I'll need the longer dual hose banjo bolt. I had the original single disc/rotor setup.
    I'll need to measure hose length to see what I need with clearance etc. LOTS to do in the next couple of weeks.
    Rear sets, bars, fork seals,emulators carbs..etc..
    Thanks for the insights!
    IMG_2745.jpg
     
    MaxPete, geedubya and Machine like this.
  4. 5twins

    5twins XS650 Guru Top Contributor

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  5. vtwinsrgood

    vtwinsrgood XS650 Member

    5Twins, Have you used these brake lines before? Are they the proper size/diameter?
     
  6. 5twins

    5twins XS650 Guru Top Contributor

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    I haven't used these exact ones but have used others from these Chinese sellers. What you need, and what most of these are, is lines with 10mm banjo fittings on them.
     
    gggGary likes this.
  7. XSLeo

    XSLeo XS650 Guru

    If you still have the old brake lines, the lowers for the duals you just need two the same length as the stock lower.
    On the upper depends on the bar height. I might get the bars before I ordered the upper line. That way you can install the bars and master cylinder then put the old upper hose on the junction block then run it to the master cylinder. Mark it where it comes to master cylinder, remove and measure.
    Leo
     
  8. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    A splitter from an XS750-850 1100 is plug and play and prolly better'n a double long banjo bolt.
     
    MaxPete likes this.
  9. arcticXS

    arcticXS XS650 Junkie

    Are you using oem discs and calipers, or reproduction parts?
    The stock (Euro) Yamaha twin disc setup is extremely heavy, and not exactly a great brake setup either.
    On my 650D, I lost around 5kg/ 11 lbs of unsprung weight by converting to a single 320 mm disc and a Brembo 4 piston caliper, combined with a 13 mm bore Brembo master cylinder. Weight savings from using an alloy front fender is also included. From memory, the oem discs were between 2 and 2.5 kg EACH, while the 320 mm ISR disc is around 1.4 kg.
    I havent used the XS with this new brake yet, but my experience with a similar brake setup on a Ducati 600 tells me it will be way better than the stock setup.
     
  10. RC4MAN

    RC4MAN XS650 New Member

    The stock components are way overbuilt as far as durability and so overweight as well.
     
  11. Grimly

    Grimly XS650 Addict

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    Ireland
    Once I'd rebuilt my Euro-spec twin disc calipers I found the standard MC was too insensitive, feeling a bit wooden.
    I experimented with a Kwack 14mm MC, and the brakes were fantastic, but the slight amount of lost motion at the calipers translated at the bars into the brake lever moving back uncomfortably close to the bar. I then fitted a 5/8" Deauville MC which is a perfect compromise, providing good feel and the bike stands on its nose without any grabbiness. Standard calipers, new pads and nothing special in there, but the brakes have never been so good.
     
    Last edited: Apr 21, 2019 at 8:50 PM
    gggGary likes this.
  12. arcticXS

    arcticXS XS650 Junkie

    Yes, caliper/ mc ratio is mostly too low on 70s bikes in general. If one should want to stick to Yamaha master cylinders, the RD 350 mc is 5/8" also, and I suspect the earlier disc brake XS has the same one, as they use the same dual piston caliper. I do not know what mc size a later model with single disc has, but it may work for dual discs as well.
     
    gggGary likes this.
  13. Skip

    Skip XS 650 Screwturner

    On my 78 Special I have the dual OEM lines,rotors and caliper set up but am using the stock master cylinder for the single caliper set up....I find the braking strong,smooth with a very light 2 finger pull....a great mod for any XS IMO
     
    MaxPete and gggGary like this.
  14. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    :agree: but go to light weight rotors, lose 7+ pounds of unsprung rotating mass, see my avatar.
     
    Skip and MaxPete like this.
  15. Skip

    Skip XS 650 Screwturner

    Totally agree with the weight advantage gggGary....but for an old purest like me, I wanted the stock appearance...but your set up sure is sharp
     
    gggGary likes this.
  16. arcticXS

    arcticXS XS650 Junkie

    Sure looks nice! May I ask what discs you are using? Any spacers required?
     
  17. gggGary

    gggGary Stop that! Top Contributor XS650.com Supporter

    like these. https://www.ebay.com/itm/93-94-95-9...062920&hash=item3b0cfc1be8:g:B1sAAOSw9Nha-IzJ
    "93 94 95 96 97 98 99 Yamaha FZR600R FZ600R FZ600 Front Brake Rotors" there's other models use them too.
    yes they need about 7mm spacers, I turn my own.
    front madness 2018.jpg
    Yamaha Motorcycle 1992 FZR600RD Front Brake-Caliper

    Yamaha Motorcycle 1993 FZR600RE Front Brake-Caliper

    Yamaha Motorcycle 1994 FZR600RFC Front Brake-Caliper

    Yamaha Motorcycle 1994 FZR600RF Front Brake-Caliper

    Yamaha Motorcycle 1990 FZR600AC Front Brake-Caliper

    Yamaha Motorcycle 1991 FZR600RB Front Brake-Caliper

    Yamaha Motorcycle 1996 YZF600RH Front Brake-Caliper

    Yamaha Motorcycle 1997 FZR600RJC Front Brake-Caliper

    Yamaha Motorcycle 1998 FZR600RK Front Brake-Caliper

    Yamaha Motorcycle 1998 FZR600RKC Front Brake-Caliper

    Yamaha Motorcycle 1995 FZR600RGC Front Brake-Caliper

    Yamaha Motorcycle 1992 TDM850 - TDM850DC Front Brake-Caliper

    Yamaha Motorcycle 1992 FZR600RDC Front Brake-Caliper

    Yamaha Motorcycle 1993 TDM850 - TDM850EC Front Brake-Caliper

    Yamaha Motorcycle 1993 TDM850 - TDM850E Front Brake-Caliper

    Yamaha Motorcycle 1990 FZR600RAC Front Brake-Caliper

    Yamaha Motorcycle 1991 FJ1200BC Front Brake-Caliper

    Yamaha Motorcycle 1992 FJ1200DC Front Brake-Caliper

    Yamaha Motorcycle 1992 FJ1200D Front Brake-Caliper

    Yamaha Motorcycle 1992 TDM850 - TDM850D Front Brake-Caliper

    Yamaha Motorcycle 1999 FZR600RL Front Brake-Caliper

    Yamaha Motorcycle 1999 FZR600RLC Front Brake-Caliper

    Yamaha Motorcycle 1996 FZR600RHC Front Brake-Caliper

    Yamaha Motorcycle 1989 FZR600W Front Brake-Caliper

    Yamaha Motorcycle 1989 FZR600WC Front Brake-Caliper

    Yamaha Motorcycle 1995 YZF600RGC Front Brake-Caliper

    Yamaha Motorcycle 1996 FZR600RH Front Brake-Caliper

    Yamaha Motorcycle 1993 FZR600REC Front Brake-Caliper

    Yamaha Motorcycle 1991 FJ1200B Front Brake-Caliper

    Yamaha Motorcycle 1991 FZR600RBC Front Brake-Caliper

    Yamaha Motorcycle 1990 FZR600RA Front Brake-Caliper

    Yamaha Motorcycle 1995 FZR600RG Front Brake-Caliper

    Yamaha Motorcycle 1995 YZF600RG Front Brake-Caliper

    Yamaha Motorcycle 1997 FZR600RJ Front Brake-Caliper

    Yamaha Motorcycle 1996 YZF600RHC Front Brake-Caliper
     
    Last edited: Apr 21, 2019 at 5:32 PM
  18. 5twins

    5twins XS650 Guru Top Contributor

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    7mm spacer? You could use an old junk stock disc for that, couldn't you.
     
  19. FWIW, the stock dual disc setup weighs about 20 lbs. I just moved to Mississippi, where the roads are bad. Those heavy wheels, 20 lbs of brakes, and upgraded springs make for an unpleasant ride.
     
    gggGary and MaxPete like this.

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