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1976 KZ400 D3 Front Brake Caliper Issues

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28 Nov 2017 20:07 #775277 by alinaaseh
1976 KZ400 D3 Front Brake Caliper Issues was created by alinaaseh
Hi all.

I recently removed my front wheel, which required me to remove the front brake caliper. Curious that I am, I squeezed the brake lever several times while the caliper was off of the disc. Both pads have fallen out and my piston is now stuck all the way out.

I made matters worse by attempting to remove the caliper from the brake hose, and rounded the bolt in the process. No amount of WD40 & plying has made it budge.

I also ended up draining the brake fluid entirely.

I'm pretty stuck - what is the plan of action here?

1976 KZ400 D3
Ft. Collins, CO

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28 Nov 2017 21:50 #775280 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Front Brake Caliper Issues
Here are 2 links to the schematics of the caliper n front hub. Some of the parts are still available from www.cmsnl.com and shipping is quick, 3-4 days.

Caliper: www.cmsnl.com/kawasaki-kz400d3-1976-cana...model_q=1976+kz400d3

Front Hub: www.cmsnl.com/kawasaki-kz400d3-1976-cana...t/52451.html#results

On my 75, the piston was also frozen inside the caliper. We soaked it in the parts cleaner for a few days and had to heat it up afterwards to get it out. Lots of corrosion, but we got it all cleaned up. I hope you get yours fixed up.

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.

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  • ThatGPzGuy
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29 Nov 2017 04:32 #775282 by ThatGPzGuy
Replied by ThatGPzGuy on topic 1976 KZ400 D3 Front Brake Caliper Issues
Hopefully you didn't mess up the piston seals. Those have been unavailable for years. I would heat the caliper up with a heat gun or hair dryer and try to work the piston back in. Be careful, you do not want to damage those seals (there are two).
Heat is also your friend for the stuck bolt. That and penetrating oil. Soak the threads for a couple of days and use heat to work that bolt out.
Good luck

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"

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29 Nov 2017 06:49 #775284 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Front Brake Caliper Issues
GPzGuy, Im wondering what the difference is between the 74-75 caliper and the 76-77 caliper...from the schematics everything looks the same...

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.

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  • ThatGPzGuy
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  • More Sparky than Speed Racer
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29 Nov 2017 15:43 #775309 by ThatGPzGuy
Replied by ThatGPzGuy on topic 1976 KZ400 D3 Front Brake Caliper Issues
I think the piston size is different. Are the part numbers the same? Too bad the KZ400.com site went away. This was much discussed on there.
I am in contact with a guy who is having them made. Not cheap but you shouldn't need to replace very often. I should have one in my hand soon for comparison. Fingers crossed.

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"

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30 Nov 2017 05:50 #775333 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Front Brake Caliper Issues
If you like, I could measure the distances between the mounting holes and what not on the 75...seems the 74-75 caliper parts are plenty vs the 76-77. My 77 cadaver has the entire kit still in tact...wonder if you could put the 74-75 caliper on in its place...

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.

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30 Nov 2017 06:41 #775337 by 650ed
Replied by 650ed on topic 1976 KZ400 D3 Front Brake Caliper Issues

ThatGPzGuy wrote: .......... Too bad the KZ400.com site went away. This was much discussed on there.
.....................


That site didn't go away. The link below goes to it. Ed

www.kz400.com/index.html

1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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  • ThatGPzGuy
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  • More Sparky than Speed Racer
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30 Nov 2017 14:42 - 30 Nov 2017 14:42 #775350 by ThatGPzGuy
Replied by ThatGPzGuy on topic 1976 KZ400 D3 Front Brake Caliper Issues
Right you are Ed. I meant the KZ400 Forum.

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"
Last edit: 30 Nov 2017 14:42 by ThatGPzGuy.

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02 Dec 2017 17:14 #775445 by alinaaseh
Replied by alinaaseh on topic 1976 KZ400 D3 Front Brake Caliper Issues
Hi all.

Here's the update. Bolt is still stuck but I managed to get the piston unstuck and put back into proper position!

New issue:
Should the smaller brake pad be loose, or should it be attached to the caliper in some way?

1976 KZ400 D3
Ft. Collins, CO

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  • DoctoRot
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  • Oh, the usual... I bowl, I drive around...
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03 Dec 2017 01:42 - 03 Dec 2017 02:00 #775459 by DoctoRot
Replied by DoctoRot on topic 1976 KZ400 D3 Front Brake Caliper Issues

Jack_Mills wrote: If you like, I could measure the distances between the mounting holes and what not on the 75...seems the 74-75 caliper parts are plenty vs the 76-77. My 77 cadaver has the entire kit still in tact...wonder if you could put the 74-75 caliper on in its place...


The caliper seal part number is the same for the caliper on the 74-79 kZ400. You were able to find a new seal? I did a whole fork/ caliper swap because there were no seals available.
Last edit: 03 Dec 2017 02:00 by DoctoRot.

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03 Dec 2017 06:05 #775466 by Jack_Mills
Replied by Jack_Mills on topic 1976 KZ400 D3 Front Brake Caliper Issues
I got the dust seal and the piston seal at www.cmsnl.com arrived in 3 business days from Netherlands for my 75kz400. Best thing to do is search their site fully and grab any parts you need all at once (saves on shipping)...

74 kz400 D1
75 kz400 D2
75 kz400 D2
75 kz400 D2
76 kz400 D3
76 kz400 D3
77 kz400 A1
78 kz400 B1
80 xl80s
81 kz440 B2
81 GL1100
81 xl80s
81 xr80
96 K1100LT
18 HAWK250
Thanks goes out to all folks who share their great knowledge teaching others about classic metric motorcycles.

Please Log in or Create an account to join the conversation.

  • ThatGPzGuy
  • Offline
  • Sustaining Member
  • More Sparky than Speed Racer
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03 Dec 2017 08:00 #775471 by ThatGPzGuy
Replied by ThatGPzGuy on topic 1976 KZ400 D3 Front Brake Caliper Issues
If you search under 1976 KZ400D3 the seals are unavailable. Partzilla shows the same thing.
What is the diameter of your caliper piston? Mine is 41.3mm.
Anyhoo, I rec'd my "new" seal from the guy on eBay so I am going to be trying that one today. Unfortunately I need to re-use the wiper seal. I'll report back the results.

Jim
North GA
2016 Yamaha FJR1300ES
1982 GPz750 R1
1974 Kawasaki H1
1976 Kawasaki KZ400
1979 Yamaha XS650 cafe'
2001 KZ1000P
2001 Yamaha YZ426
1981 Honda XR200 stroked in an '89 CR125 chassis
1965 Mustang
1967 Triumph GT6
1976 Bronco
"If you didn't build it, it's not really yours"

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