The ZT 190 Brake Upgrade

[Jakg]

I'm still wrestling with it in my head, at the front at least.

Assuming I buy all the parts (calipers, carriers and hoses), how exactly do I swap it all over? Is there a guide anywhere?

[mark_bonsai]

Originally Posted by Jakg

I'm still wrestling with it in my head, at the front at least.

Assuming I buy all the parts (calipers, carriers and hoses), how exactly do I swap it all over? Is there a guide anywhere?

It's not a difficult job at all Jack, assuming of course you have some basic mechanical experience. The only possible headache is bleeding the brakes after the new calipers are fitted. However, taking your time with someone assisting to press the pedal, or use one of the one man setups (Eezi-bleed, etc) which are cheap and easy to get hold of (Halfords), it's no bother.

I actually did this exact job on mine yesterday and it only took a few hours It would have been quicker if I hadn't been doing it on my knees in the drive.

You'll need the calipers and carriers (there's a second hand set on ebay at the moment for £50 delivered), discs and pads. I thought the hoses were different on the 190 but they're not.

I'll post up a step by step later unless someone beats me to it, but feel free to PM me if you want further details.

[T-Cut]

Originally Posted by mark_bonsai

I actually did this exact job on mine yesterday

How did you swap the disc splash guards?

TC

[mark_bonsai]

No, left them as is. According to Rimmers, they're the same across the range. Must admit, not checked the EPC though.

[T-Cut]

Originally Posted by mark_bonsai

No, left them as is. According to Rimmers, they're the same across the range. Must admit, not checked the EPC though.

The 190 discs have a 63mm larger diameter than the rest. The splash guards are of similar diameter and lip towards the disc on the periphery. I can't see how a larger disc can be fitted with a smaller disc guard. The main reason I ask is cos the standard way requires removal of the hub to release the guard which encircles the drive shaft. This makes it a big job. However, a recent discussion I had involved cropping away the guard so it will slide over the drive shaft with the hub still in place.

As you say, the Rimmer listing shows only one splash guard across the range. That seems odd to me, but there it is. I think I'd check that the splash guard does actually cover the outer face of the 190 disc or they will suffer errosion from road spray.

TC

[Sonus]

Are the 190 brakes larger than the 1.8T 160? I'd like some more initial bite to my brakes.

[mark_bonsai]

The fronts on the 190 are 325mm as opposed to 282mm (maybe a few mm out).

The lip on the shields doesn't come close to the discs so they fit just fine. They must do as I've done 60 odd miles since fitting them with no problems. I'm also not the only one to do this and I'm certain no one else has changed the shields. If I get a few spare minutes tomorrow, I'll pull a wheel off and take some photos. I've also got some 190 shields in the workshop so I'll run a tape across one of those.

[T-Cut]

Originally Posted by Sonus

Are the 190 brakes larger than the 1.8T 160? I'd like some more initial bite to my brakes.

I think you also require 18" wheel rims to clear the calipers.

TC

[pab]

glad it was as simple as discussed...did you take step by step pictures?

suppose you can assist me when i do the upgrade.

[T-Cut]

Originally Posted by mark_bonsai

I'll pull a wheel off and take some photos. I've also got some 190 shields in the workshop so I'll run a tape across one of those.

OK thanks, that will be interesting.

TC