How-To add Brembo caliper and a 18" spoked rim

Bushyeyed1

Cafe Racer
Top Contributor
Messages
845
Reaction score
1,448
Points
143
Location
Wahiawa, HI
Well I got my new brake master cylinder. Unfortunately the clutch lever didn't just bolt on magically so I'll be doing some redneck engineering on it tomorrow. You will have to follow that on my build thread though.
7757DC84-780C-409C-8888-1882B21A5D0C.jpeg
 

arcticXS

XS650 Guru
Top Contributor
Messages
2,125
Reaction score
3,340
Points
263
Location
Tromsoe, Norway
I just realized that an 18" rim will give slightly more clearance between spokes and caliper than a 19" rim, due to the slightly sharper angle of the spokes.
On my stock 19" front wheel, I ended up with 23 mm disc offset, equivalent to a 13 mm spacer on a common Ducati disc. That left only 2 mm clearance between disc buttons and the fork leg. However, I used the "65 mm" Brembo caliper.
 

SEd27

XS650 Addict
Messages
177
Reaction score
409
Points
63
Location
Kelowna, British Columbia
I just realized that an 18" rim will give slightly more clearance between spokes and caliper than a 19" rim, due to the slightly sharper angle of the spokes.
On my stock 19" front wheel, I ended up with 23 mm disc offset, equivalent to a 13 mm spacer on a common Ducati disc. That left only 2 mm clearance between disc buttons and the fork leg. However, I used the "65 mm" Brembo caliper.

arcticXS,

Thanks for confirming this. I am using a stock width 19” front and had to file the back of the caliper to clear the spokes.

Because I used the recommend Motolanna disc, I could not add a shim washer on the axle like bushyeyed1 (it would have thrown the spacing out).
 

Bushyeyed1

Cafe Racer
Top Contributor
Messages
845
Reaction score
1,448
Points
143
Location
Wahiawa, HI
arcticXS,

Thanks for confirming this. I am using a stock width 19” front and had to file the back of the caliper to clear the spokes.

Because I used the recommend Motolanna disc, I could not add a shim washer on the axle like bushyeyed1 (it would have thrown the spacing out).

I also am using the MotoLanna spacer disc but of course have 18” rims. I only added the washer in between the dust cover and fork leg because once torqued down it would sandwich the fork a little bit causing the spokes to be too close to the caliper. So the washer didn’t change the alignment of the disc and caliper for me. It could be the difference of rotor disc offset. What disc are you using with your setup?
 

SEd27

XS650 Addict
Messages
177
Reaction score
409
Points
63
Location
Kelowna, British Columbia
I also am using the MotoLanna spacer disc but of course have 18” rims. I only added the washer in between the dust cover and fork leg because once torqued down it would sandwich the fork a little bit causing the spokes to be too close to the caliper. So the washer didn’t change the alignment of the disc and caliper for me. It could be the difference of rotor disc offset. What disc are you using with your setup?

Using an aftermarket Arashi SRX400 disc with the Motolanna spacer

With everything buttoned up for the mockup, the disc is centred in the caliper.

Will have have to recheck the spacing with a shim washer, as I like the security of the built in stop to keep things away from the spokes.
 
Last edited:

Bushyeyed1

Cafe Racer
Top Contributor
Messages
845
Reaction score
1,448
Points
143
Location
Wahiawa, HI
Using an aftermarket Arashi SRX400 disc with the Motolanna spacer

With everything buttoned up for the mockup, the disc is centred in the caliper.

Will have have to recheck the spacing with a shim washer, as I like the security of the built in stop to keep things away from the spokes.
Sorry I guess I should have checked the prior page that you posted the rotor disc. I am not sure of the spec differences between our discs, but mine appears to have about a 5mm offset and thickness is 5mm with a min of 4mm. From what I can tell from looking at your disc on Ebay it has a slight offset as well but a minimum thickness of 4.5mm. The washer is only about 2 mm thick so I am not sure if you would rather have it slightly off or grind your caliper. I double checked mine just for shits and giggles and I have 5mm of brake pad on either side of the rotor disc. The spokes have about 5-6mm clearance from the raised lip on the back of the caliper. It appears centered and the caliper pistons don't look significantly on one side or the other. It is also just my opinion, but if the caliper piston is slightly off a mm or two it should not be that bad.
 
Last edited:

SEd27

XS650 Addict
Messages
177
Reaction score
409
Points
63
Location
Kelowna, British Columbia
Sorry I guess I should have checked the prior page that you posted the rotor disc. I am not sure of the spec differences between our discs, but mine appears to have about a 5mm offset and thickness is 5mm with a min of 4mm. From what I can tell from looking at your disc on Ebay it has a slight offset as well but a minimum thickness of 4.5mm. The washer is only about 2 mm thick so I am not sure if you would rather have it slightly off or grind your caliper. I double checked mine just for shits and giggles and I have 5mm of brake pad on either side of the rotor disc. The spokes have about 5-6mm clearance from the raised lip on the back of the caliper. It appears centered and the caliper pistons don't look significantly on one side or the other. It is also just my opinion, but also the caliper piston slightly off a mm or two should not be that bad.

Thanks for the measurements. That is super helpful. Going to try and get into the garage tonight to verify a few things.
 

SEd27

XS650 Addict
Messages
177
Reaction score
409
Points
63
Location
Kelowna, British Columbia
@SEd27 were you able to get your setup running on your bike?

No, I hit a bunch of snags, but I am close.

There were issues with painting the caliper. I did not prep correctly and it resulted in two addition complete repaints after the initial spray (even using the correct caliper paint).

When I went to reassemble the caliper intervals, I discovered that misplaced the caliper body seal/ o ring and had to re-order.

I also found that I purchased the wrong length banjo bolt. Apparently, there are two common lengths for the Brembo caliper - 19mm and 25mm. I accidentally ordered the shorter and found I needed the longer one. Had to place another order.

Shipping got delayed due the Covid crisis which resulted in 5-6 week wait.

I finally got everything sorted this week and went to install brakes and found the my vacuum bleeder had a crack in it and would not hold air. Off to the store to get another.

Fingers crossed I will have everything buttoned back up this weekend.:D

How are you finding your setup after some more miles in the saddle?
 
Last edited:

350GUY

XS650 Enthusiast
Messages
71
Reaction score
40
Points
18
Location
Canada
Hard to get a good picture, but in my case the Aprilia Mana 850 disc is a perfect fit. I almost got a Ducati monster disc, but liked the minimalistic look of the Aprilia floating disc. There is so many other after market brands that look good too.

Aloha Bushy - If I may ask, of which year is Aprilia Mana 850 model is the disc off?
 

350GUY

XS650 Enthusiast
Messages
71
Reaction score
40
Points
18
Location
Canada
Thank you Sir, much appreciated. For the Brembo brake calipah, would you happen to know on which bikes they come as standard fitment? Perhaps I could find one on ebay at a reasonable price than a new one.
 

Bushyeyed1

Cafe Racer
Top Contributor
Messages
845
Reaction score
1,448
Points
143
Location
Wahiawa, HI
Thank you Sir, much appreciated. For the Brembo brake calipah, would you happen to know on which bikes they come as standard fitment? Perhaps I could find one on ebay at a reasonable price than a new one.

Mine was listed for sale used as 91-96 Ducati M900 M750 900SS 700SS 748 916. If I was a betting man you not only can find the caliper on Ducati’s but also Aprilia models. Use the part numbers for the first part of this thread I posted in the how to and also search for Brembo caliper 40 mm on eBay and it should bring some up.
 

350GUY

XS650 Enthusiast
Messages
71
Reaction score
40
Points
18
Location
Canada
Mine was listed for sale used as 91-96 Ducati M900 M750 900SS 700SS 748 916. If I was a betting man you not only can find the caliper on Ducati’s but also Aprilia models. Use the part numbers for the first part of this thread I posted in the how to and also search for Brembo caliper 40 mm on eBay and it should bring some up.
Bushyeyed: You Sir are a rock star! I will proceed per your advise. Thank you so much and ride safe.
 

stinky78

XS650 Addict
Messages
136
Reaction score
195
Points
43
Location
Melbourne Aus
hi Bushy, I just re-read this and was a bit confused, what width are your front and back rims? From reading it I thought the front was 2.15 but then you said you didn’t know if a 2.5 would fit and I wasn’t sure if you meant front or back.
 

Bushyeyed1

Cafe Racer
Top Contributor
Messages
845
Reaction score
1,448
Points
143
Location
Wahiawa, HI
hi Bushy, I just re-read this and was a bit confused, what width are your front and back rims? From reading it I thought the front was 2.15 but then you said you didn’t know if a 2.5 would fit and I wasn’t sure if you meant front or back.
So there is a difference in the way the spokes are on a front and rear rim. I purchased a rear rim for the front that was 2.15” and the spokes that will adapt a rear rim to the front hub. I can’t verify if a wider rim will fit with the type of brembo set up I did since my spokes were so close on the 2.15”. It might work but I don’t want to tell you it will for sure. I think the slightly thinner rim for the front is probably better for handling curves.
 
Top