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SubyRS
Can anyone verify if the brake calipers and rotors on the 89 FZR400 and 89 FZR600 are identical?

I find some very interesting similarities in parts numbers between the two models for the forks, brake discs, calipers and brake hoses. Even the front wheels look the same.

The 400 is the 1WG prefix and the 600 is the 3HE.


1WG-25810-11-00 CALIPER ASSY LEFT
3HE- 2580T-02-00 CALIPER ASSY LEFT

3CV- 25830-10-00 DISC BRAKE ASSY
1WG-25830-02-00 DISC BRAKE ASSY

3HE- 23102-00-00 FRONT FORK ASSY L (L.H)
1WG-23102-00-00 FRONT FORK ASSY L (L.H)

3HE- 25873-01-00 HOSE, BRAKE 2
1WG-25873-01-00 HOSE, BRAKE 2

1WG-25168-00-UA WHEEL, CAST FRONT
3HE- 25168-00-UA WHEEL, CAST FRONT
Dru86
Just did a quick google search to refresh my memory on how the part no. work



Plus this post explains it well:

In the case of XV920 rings, the part number is 5H1-11610-00-00.

5H1 designates the first Yamaha model using this part.

11610 designates piston rings

The first "00" means the original part for this model. If the part was subsequently revised, these 2 digits would be "10"; next revision "20", etc. In the case of piston rings, "00" means standard size, "10" means 1st oversize, "20" means second oversize.

The second "00" refers to a color code. In the case of piston rings, color doesn't matter. In the case of fenders or sidecovers, the part numbers for different years of the same model may differ only by the color code - the last 2 digits.

With a little research, you too can determine that the same connecting rod (5A8-11650-00-00), wrist pin (5A8-11633-00-00), intake valve (2J2-12111-01-00), and exhaust valve (5A8-12121-00-0) are used in XV920s through XV1100s, but not XVS1100s. The same crank bearings (5G5-11656-00-00) are used in the XV700s through the XVS1100s. The same piston rings are used in XV1100s and XVS1100s (1TA-11610-00-00), but different rings in the XV1000 (5A8-11610-00-00).

And now, a real secret: the system for hardware.

The first set of digits identifies what kind of hardware:
98501 = panhead screw
91311 = allen head screw
92990 = lockwasher
etc.

The next set of digits give the dimensions - 05010 is 5mm diameter, 10mm in length.

For example, want to replace the crankcase cover screws with stainless steel screws? You need 3 6x20mm (91311-06020), 9 6x25 (91311-06025), 8 6x30 (91311-06030) and 4 6x40mm (91311-06040). And don't forget to use antiseize.

With these codes, you can replace fasteners not covered in the usual kits of chrome/stainless fasteners.

Don't forget that some fasteners are high tensile strength, so you shouldn't substitute a weaker fastener that's the same dimensionally


So in other words they could be completely different.
SubyRS
I guess that's one way of saying "I don't know". What I am looking for is someone that has actually interchanged the parts in question and can verify that they do indeed work.

The manufacturer makes and designates a specific volume of parts for a specific vehicle. Many parts can be identical, but "reserved" for different applications and so designated with slightly different part numbers. Interesting about the bolts. Thanks for that. I never use stainless bolts on my motorcycle though.

The FAQ section of this web site says the two piston calipers are interchangable between the 400 and 600 for 88/89. I need to confirm that before ordering the new parts.
But the FAQ section also sort of contradicts itself when it says that the wheels/rotors/calipers must stay together and be interchanged as a unit to work between the two bikes.

Hence the need for more confirmation about what actually works and what someone thinks should work.
Dru86
well I do know a few of them:

Wheel wise you can use either, they both take the same axle and have the same bolt pattern/offset for the discs, the 400 is a fair bit lighter though (and looks better IMO).

Forks: The 89 fzr600 has a 80mm caliper spacing(the 90 upwards has a 100mm) and takes 300mm discs. The fzr400 also has the 80mm spacing but takes the smaller 280mm discs hence why you must use the discs and forks from the same model.

No idea why the calipers and hoses are different though, I thought that they were the same between the early fzr400 and the early fzr600 but on looking they also take different brake pads. Edit: It may be to do with the offset of the discs.
SubyRS
Thanks. It's all pretty obscure at best.

But GOOD NEWS! EBC Prolite Rotors are available once again for the 88/89 FZR400. I just confirmed and ordered all three Prolite discs and EBC organic pads for about $650, which is cheaper than just two Yamaha rotors. I don't know if EBC made more or if old stock was found.
SubyRS
Well, the Prolite rotors just came today.

Evidently there has been a design change along the way. The left rotor MD2020LS has drilled holes and tight rivets. The right rotor MD2020RS has no holes and the rivets are set for full floating. They are ordering another right disc so hopefully I can get a matched set or it all goes back.


mossy1200
QUOTE (SubyRS @ Jun 26 2008, 08:16 PM) *
Well, the Prolite rotors just came today.

Evidently there has been a design change along the way. The left rotor MD2020LS has drilled holes and tight rivets. The right rotor MD2020RS has no holes and the rivets are set for full floating. They are ordering another right disc so hopefully I can get a matched set or it all goes back.



bikebandit have sent me one disc and cancelled the other as it is not avaliable.i have one disc of a set.
Disappointed by the sending of half an order without contacting me first.
Cafe Racer
I did the swap on my FZR400.

In order for me to run with the '03 R6 Calipers I had to use an FZR600 set of forks. Which then required me to use a set of FZR600 rotors.

The picture shows the difference in rotor size between the 400 and 600cc bikes. If you were to look at the rotors profile you would also see the the 600cc rotor was "dished" at the hub.

Miguel
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