2005 ZX10R Front End Diagnosis

GreyGhost said:
So it seems to be affected by suspension loading? That would lead me to look at forks/triples/bearings but you have already torn all those apart. What about tires? Have you changed the tire in all of this mess?
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Not yet. But its now got me suspicious.
 
Are you sure those are the right diameter rotors? They look to be aftermarket (EBC?). The pads are only contacting 2/3 of the rotors, and looking at the caliper pic, you should see the top of the rotor just proud of the tops of the pads. Can't even see the top of the rotor in your pic. Brembos use different width spacers for different size rotors, as well. Nissin should be the same. Maybe too thick spacers?

OEM rotor wear, for reference.
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I spy spacers between the calipers and fork bottoms. Stock rotors and stock pads doesn't need those. 10mm larger rotor should need 5mm spacers. I don't know if the swept width on the larger rotors is meant to be wider, thus leading to pads not covering it all if wider pads aren't used. 14R calipers are a common upgrade to replace the stock (rubbish) calipers and I haven't seen this come up as an issue.
 
Brian P said:
I spy spacers between the calipers and fork bottoms. Stock rotors and stock pads doesn't need those. 10mm larger rotor should need 5mm spacers. I don't know if the swept width on the larger rotors is meant to be wider, thus leading to pads not covering it all if wider pads aren't used. 14R calipers are a common upgrade to replace the stock (rubbish) calipers and I haven't seen this come up as an issue.
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Yeah the spacers work out to a more customized 4mm which was the absolute minimum I could get without risking the rotors contacting the calipers. I measured with a digital (measurement) caliper and got 3.99mm and 4.00mm respectively. I wanted as much contact as I could get and this was found through trial and error. I did the math, and it was a 5mm I needed for the rotor diameter (310mm), but it created too much of a gap.

I would like more contact - but even then I couldn't imagine the stopping power with MORE force. I think my eyeballs are still out on the street after releasing from their sockets.

👀
 
Has OP used a dial indicator yet?
 
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