a 1980 KZ440 mast.cyl. w/ 1978 KZ 400 bike

Hi All...

I have a 1978 KZ400 project bike (i work on it when it in the winter when it is too cold to ride my F650).

Last winter i worked on the front end a little (forks, etc..) and this winter i need to deal with the front brakes...

I needed a new front mast.cyl. and got one from ebay.

It is for a 1980 KZ440 though (and i assumed it would be similar to the 1978 KZ400). It is, but not 100%.

The 1980 KZ440 mast.cyl. has some kind of "pig tail" on it with 2 connectors at the end (it originates at the point where the lever meets the main housing). My assumption is that this has something to do with the brake light...?

The 1978 KZ400 mast.cyl. (original that is damaged) does NOT have this "pig tail" but midway down the brake line there is a connector of sorts (with 2 little prungs coming out of it).

Am i safe in assuming:

- these prungs/connectors are involved with the brake light

- that since i am using the old lines (though may update them) with the prunged connector midway down the line, that i can simply cut the "pig tail" line of the 1980 KZ440 mast.cyl. that am using to replace the 1978 mast.cyl. system

?

thanks...

- prime
(ps. i wonder if a couple of pics might make this easier?)

primemover wrote:

.....i wonder if a couple of pics might make this easier?...

Oh boy would it!

It sounds like you're describing the brake light pressure switch on the '78 unit. I just don't know.... pics would pretty much nail it for me/us....

will do (but prob will not be able to until tomorrow afterwork)...

thanks...

- prime

I don't know if this pic link will work, but...


This is a '80 master cyl.
the item 15 is a brake switch. It sounds like what you described....

YES! YES! YES!

i tried to find a pic like that at "bikebandit.com" but they did not have anything (that i could find - plus a few of their pic links had X on them)...

is that one from bikebandit.com?

i just found this pic (of the 1978 - see below) and item #25 is listed as a "brake switch"...


i guess (in this singular case) my assumptions were/are correct?

i.e., i can remove that switch wire from the 1980 mast cyl. and simply use the standard switch that is part of the 1978 system?


primemover.smugmug.com/photos/225478190-M.gif



(ps. i'm trying to post a pic - no luck)

Post edited by: primemover, at: 2007/11/25 21:10

primemover wrote:

...is that one from bikebandit.com?

Nope - from Kawasaki themselves. Use the link on this forum... on the right of the page, in "THE ESSENTIALS" list...

i just found this pic (of the 1978 - see below) and item #25 is listed as a "brake switch"...


i guess (in this singular case) my assumptions were/are correct?

i.e., i can remove that switch wire from the 1980 mast cyl. and simply use the standard switch that is part of the 1978 system?...

Yep, that's it! Can you use the switch? Well, I guess if its still physically in place, yes, absolutely. As long as there is pressure in the line to pressurise the switch, you're good. The unused one on the new master cyl will still be there if the '78 one fails...

that's great!

thanks!

i'll be spending the next few weeks (only have an hour here/hour there) to clean up the 1980 master cyl. and repaint it, make sure the lines look good (on the old) and deal with checking out the brake pads...

i'll be back!

you were a great help!

- prime

Hi...

Not sure about this, but in that image #5, 6, 7, 8 are all part of a "piston" to actuate (spelling) the front brake...

the mast. cyl. i'm working on, it looks as though there is also some kind of "boot" that goes around this piston...

the mast. cyl. was in pretty nasty shape (as if some brake fluid had leaked on it)...

i'm cleaning it up now (looking pretty good - getting down to the metal), but am concerned that if i do NOT inspect this piston area prior to repainting, i could have to do it all over again (if indeed there is a leak coming from here)...

should i dismantle this section (#5-? is this a good/bad idea...

thanks so much...

- prime

hey....

decided to "go in" anyway and take a peak at those parts...

no big deal (really)...

the dust cover (boot as i called it) WAS indeed punctrued!
(2-3 places!)...

found a supplier online ( www.babbittsonline.com ),
placed an order (~ a $5 part) and also ordered a new diaphram (old was prob ok, but figured i was already paying for postage)...



i'll paint the mast. cyl. in the next few days while waiting for the boot...

happy camper!

- prime