1978 Front Master Cylinder Rebuild

Hey everyone, I'm new to the Z1 world and am looking for a little direction. I just picked up a 1978 Z-1000 and the front brake piston appears to be frozen. I read a few forums on this site about where to get the rebuild kit, but I'm having trouble removing the original piston. Does anyone have instructions or possibly a video? I have the MC removed from the bike abs the brake line and lever removed. I couldn't figure out how to remove the switch, but it doesn't really to appear to be in the way. I'm sure I'll have more questions later. I ordered a repair manual and I'm sure that will help me, but that is about 2 weeks away and I'm impatient. Please help. Thanks

There are service manuals on the internet for free download. Found one for my 750 anyway. You might want to do some searching via google.

Typically the piston comes out after you remove a snap-ring or retainer clip. Look closely at the master in the area around the plunger and you should be able to figure it out. Once the retainer is removed the piston will pull out...if you can get it unstuck that is.

Unfortunately, when the piston freezes like you mention that typically means there will be corrosion in the aluminum master cylinder body. Be sure to inspect the bore carefully before ordering a repair kit. The cylinder may not be serviceable, or at least not economically.

Any idea where i would be able to find a OEM replacement master cylinder? I opened mine up and it has hard plastic sleeves within the bore. I'm guessing that was a repair that was probably done to it at one point.

No eBay APP ID and/or Cert ID defined in Kunena configurationI bought one of these 4 yrs. ago, & It works as good as the original, although I don't know if it makes that much of a difference , but when I installed this one , I also installed new steel braided brake lines
Pete

joey513pressnell wrote: Any idea where i would be able to find a OEM replacement master cylinder? I opened mine up and it has hard plastic sleeves within the bore. I'm guessing that was a repair that was probably done to it at one point.

In order to try to help you we need to know exactly what motorcycle you own. You state you have a "1978 Z-1000", but that does not reveal what model bike you have. The exact model matters since Kawasaki made 5 different KZ1000 models in 1978, and they do not all use the same parts. In order to look for and possibly find the correct parts it really is necessary to know which model you have. Once you sort that out, please add the year and model to your signature line as that precludes you from needing to remember to include it in every posting. Here are the 1978 KZ1000 models and the part numbers for their front master cylinders. Ed

KZ1000-A2 KZ1000 (1978) 43015-1007
KZ1000-A2A KZ1000 (1978) 43015-1007
KZ1000-B2 KZ1000 LTD (1978) 43015-1009
KZ1000-C1 Police 1000 (1978) 43015-1009
KZ1000-C1A Police 1000 (1978) 43015-1009
KZ1000-D1 Z1R (1978) 43015-1012

Ed, I appreciate the guidance. I am new to the KZ world and new to this forum. How exactly would I find out which model I have? The only things I see on the bike indicating a different model are on the side plate that quickly removable it says "KZ 1000 ST" and then an engine number which I listed below. Again I appreciate the help. I am used to restoring old cars, this will be the first "older" bike I have restored.

KZT00EE001646

-Joe

Thanks Pete, that looks almost identical to mine. Glad to know its available if needed.

-Joe

No eBay APP ID and/or Cert ID defined in Kunena configurationThanks for the info. Since your frame shows "KZ 1000 ST" am I correct in assuming the bike uses a drive shaft rather than a chain to turn the rear wheel? (The "ST" stands for "Shaft Transmission.") If so, you bike most likely is not a 1978 model; odds are it is a 1979 model which makes it a KZ1000-E1 model. Keep in mind, like cars, bike models begin being built toward the end of the year prior to their model year. So for example a bike built in November, 1978 is actually a 1979 model. The engine numbers for the 1979 ST began with KZT00EE-000101, so it makes sense that yours with number KZT00EE001646 is a 1979. Here is a reference that shows the various models - www.z-power.co.uk/merchantmanager/view_information.php?pId=21

Having said all that, the part number for the front master cylinder assembly is 43015-1032.

Here's a reference that shows 43015-1032 as the part number for the KZ1000-E1 (but it's missing the diagram)-
www.dealercostparts.com/pages/oemparts#/...0-E1-1979/070082E-13

Here's a diagram that shows 43015-1032 -
www.kawasaki.com/Parts/PartsDiagram/143738/1981/KZ1000-J1

Here's a used 43015-1032 master cylinder that the seller says has been disassembled, cleaned inside and out, and tested fine; just needs the outside painted. The seller has a money back guarantee.