2004 zephyr...need help.

  • mykznme
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2004 zephyr...need help.

11 Feb 2026 19:37
#921412
My son's friend just got an 04 zephyr.
my first question is where to get reliable brakes front/rear.

There has to be someone that knows about these bikes so please let me know..
Im sure I'll have more questions as we go through it..

R.I.P. Odd Ivar

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  • Wookie58
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Re: 2004 zephyr...need help.

12 Feb 2026 00:16
#921417
Welcome from the UK - when you say "reliable brakes" what is the issue ?
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  • Stereordinary
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Re: 2004 zephyr...need help.

12 Feb 2026 08:36
#921429
Is it a 550, 750, or 1100 Zephyr? The stock brakes on any of them work quite well if serviced properly. There are some improvements that can be made though, most notably installing braided stainless steel brake lines. 
A breeze from the west.
‘90 Kawasaki ZR550 Zephyr
‘11 Triumph Daytona 675 SE (project bike)
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Re: 2004 zephyr...need help.

12 Feb 2026 08:55
#921432
I dont have the bike in front of me but I was with him when he bought it.
the pads are a non issue but the pistons on both front calipers are pushed out and he hasn't been able to find much for replacements. 
He did find one pair of F calipers on ebay but they looked even more clapped out than what he has.
I suggested letting pressure off and trying a c clamp to bring the pistons back in.
Im weary about messing with them too much though. Brakes on a bike are the last thing that you want to go farting around with..

R.I.P. Odd Ivar

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Re: 2004 zephyr...need help.

12 Feb 2026 09:00
#921433
I suppose I should've started with this...lol
it's a 2004 zephyr 750.
It his first bike,he bought it for $300.
it's going to be a project for sure but ive seen worse.

R.I.P. Odd Ivar

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  • Nessism
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Re: 2004 zephyr...need help.

12 Feb 2026 09:11 - Yesterday 04:24
#921434
Common problem with old bikes that weren't serviced properly, ie, replacing the brake fluid regularlly.

Remove the calipers, use compressed air to pop out the pistons, and clean out the grunge.  Replace the pistons if they are pitted.  Replace the piston seals and boots, and reassemble.  Basic work.  Do the whole system, including the master, and replace the brake lines.  Buying used parts in the hope of finding better is a fools play.  New parts like pistons and seals are still available.

 
Last edit: Yesterday 04:24 by Nessism.
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Re: 2004 zephyr...need help.

12 Feb 2026 09:12
#921435
Rebuilding the callipers with new seals and possibly pistons is a better option to buying anything used which is going to also be 20 years old with unknown heritage !

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  • hugo
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Re: 2004 zephyr...need help.

12 Feb 2026 11:58 - 12 Feb 2026 12:01
#921441
Could you show a picture of this bike???    ....To me the fact you are not the owner, ..but a friend of the owner's father...does not bode well for info or solutions. .     As far as I know there were never 2004 Zephyrs.   Last Zephyr in Japan were manufactured in 1998.     In the 2000s Kawaski switched to exporting the ZR-7 only, and that was a modifycation of the Zephyr 750.  Both were called ZR-750.    The ZR-7 was a  gap solution to counter the Suzuki SV650 before the Kawi Versys 650,...which stopped production of ZR-7s in 2004. .  

Is this a ZR-7???  The Zephyr had uneven caliper pistons size (one big one, one small one),....in the ZR-7 were same size..   
Last edit: 12 Feb 2026 12:01 by hugo.

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  • TexasKZ
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Re: 2004 zephyr...need help.

Yesterday 21:58 - Yesterday 22:01
#921453
It looks like the ZR-7S was sold in Canada in 2004.

I have bought brake parts from Brakecrafters and have been well pleased with them

brakecrafters.com/pages/search?Year/2004.../ZR7S/Submodel/ZR750

Also, according to Partzilla, most of the factory parts for the 2004 ZR-7S are still available, save the pads and calipers.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

www.kzrider.com/11-projects/620336-anoth...uild-thread?start=24
Last edit: Yesterday 22:01 by TexasKZ.

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Re: 2004 zephyr...need help.

Yesterday 07:13
#921457
get it running first. before buying any brake parts. but in the mean time. he should inspect the caliper pistons to see if they're salvageable. the K&L catalog lists pistons and kits for the zr750h. some parts are still available from the dealer but are pricy. 

ZR750-H4 (ZR-7S) (Canada) >>  www.partzilla.com/catalog/kawasaki/motor...canada-only-zr750-h4 >> choose category then click on a part to get to the x-ref.

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Re: 2004 zephyr...need help.

Yesterday 10:25
#921460
Thank you guys for the replies.
I agree that I should have the bike infront of me before asking specific questions but I know nothing of this model and back in 2004 when I bought my KZ,this forum was my main go to for info.
I no longer have my kz but when my son's freind bought his(whatever it is) i figured there would be no better place to ask for info.
I sent him the link and told him to join so hopefully he'll do that and be able to give yall more info,pics,etc...

I do however have the tank so I could take a pic of the sticker for vin/model ID if it would help.

R.I.P. Odd Ivar

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Re: 2004 zephyr...need help.

Yesterday 10:30 - Yesterday 10:35
#921461
   

This is the sticker on the tank and the petcock that was on it.
The petCock looks to have been replaced. 
I pulled these out of the tank.
A pre filter for what I assume is from the old petcock,a spring and I have no clue what the plastic bit is from...

R.I.P. Odd Ivar
Last edit: Yesterday 10:35 by mykznme.

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