I’m in the midst of upgrading the braking on my ‘83 R65 and thought I would share my experiences as I go.
First up is replacing the warped rotor. As anyone who’s called the dealer likely found out the OEM replacements only exist in the country in single digits and they’re something to the tune of $300+. Speigler used to offer a service where they replace just the disc on your existing OEM rotor hub. According to them they no longer can get the discs and have discontinued this service.
You can however get the disc from Braking. I got one on eBay for $99 shipped. Here’s how to install it:
Here’s what you get.
Laid over stock rotor.
Use a punch to mark the center of the rivets.
Cover the hub hole to avoid shavings getting in there. I used a rubber stopper.
Use a drill bit about the same size as the rivet to take most of the meat off. Stop before you get into the rotor to avoid going too far and eating into the hub. (Left)
Use a grinder to take off the rest. (Right)
Use a punch to knock out the rivet (right).
Pull the rotor off and clean the rotor hub of all shaving and debris.
Clean the new rotor with brake clean.
The kit comes with two length bolts. Use the longer ones. Install the hardware in this order: Bolt, countersink spacer, wavy washer, rotor, washer, nut.
FYI the bolt and nut are pretty low grade and I had one pair bind on me that I then had to chase with a tap and die. I would have swapped them out for stainless if I had them in stock. Snug them up by hand with a ratchet to avoid them cross threading.
The Braking directions say to use OEM torque specs but of course our bikes don’t list this. I went with 10 ftlbs because that’s what my KTM rotor calls for.
Here it is all buttoned up:
Next I’ll be tackling making a 4-piston Brembo caliper from the R/K1100 work on the bike.
I got some EBC organic pads (FA246) for $20 shipped and the caliper for $30 shipped, both on eBay. Just waiting for the parts to come in.