New Discs and pads

Seems odd that both front calipers are doing the same thing.

Any unusual clacking noise from the front end when crossing railroad tracks while riding?

Good Fortune!

Not positive about caliper on this parcular model, but "floating" caliper moves back and forth over bolt shafts.

This area of movement is supposedly protected by rubber seals against dust etc from getting inside and abrading the bolt and caliper hole and wearing out the supposedly smooth clean slightly lubricated area of interplay between caliper and bolt shaft.
The rubber seals rot and deteriorate over time, which allows road crud and grit etc into the supposedly pristine floating area.

When a caliper is excessively loose in the floating area, it may emit a clacking sound when shaken, such as when riding over railroad tracks.

Enough slop between caliper hole and bolt shaft might result in uneven pad wear.

Good Fortune!

Don't know anything about newer floating disc's.
But, Older KZ 4 bolt hole discs were thinner on a 650 compared to a 1000.
Did you change the disc's with a larger model bike?

I was looking at all the spare calipers I have and the area that you marked in blue on yours is machined off on mine. I wonder if your calipers are mis-machined. Why don't you pull them from the mountings and post a half dozen good pictures from different angles so we van see them a bit better. You, in fact may have a bad set of calipers.

This diagram is from kawasaki.com, and might not be same caliper, but is the only 1983 KZ650 shown there:

KZ650-H3 (CSR): FRONT BRAKE ('83 H3)

The 92028 bushing would likely wear prematurely upon failure of 49006A seals.

Good Fortune!

[Click on image to enlarge view.]



[Add checked items to Pick-List] REF NUMBER PART NUMBER DESCRIPTION QUANTITY US CA CN REMARKS
[Add to Picklist: 13070-1026]
13070 13070-1026 GUIDE,PAD 2
[Add to Picklist: 41080-1048]
41080 41080-1048 DISK,FRONT 1
[View Supersession]
[Add to Picklist: 43020-1096]
43020 43020-1096 PISTON-COMP-BRAKE 1
[View Supersession]
[Add to Picklist: 43041-1113]
43041 43041-1113 CALIPER-ASSY,FR 1
[Add to Picklist: 43045-1007]
43045 43045-1007 SHAFT,CALIPER 1
[Add to Picklist: 43045-1008]
43045A 43045-1008 SHAFT,CALIPER 1
[View Supersession]
[Add to Picklist: 43049-002]
43049 43049-002 RING,PISTON SEAL 1
[View Supersession]
[Add to Picklist: 43056-003]
43056 43056-003 BREEDER 1
[Add to Picklist: 43057-003]
43057 43057-003 CAP,BREEDER 1
[View Supersession]
[Add to Picklist: 43082-1025]
43082 43082-1025 PAD-ASSY-BRAKE 1
[Add to Picklist: 49006-1043]
49006 49006-1043 DUST SEAL,PISTON 1
[Add to Picklist: 49006-1044]
49006A 49006-1044 DUST SEAL 2
[View Supersession]
[Add to Picklist: 92001-1951]
92001 92001-1951 BOLT,SOCKET,8X30 7
[View Supersession]
[Add to Picklist: 92001-1510]
92001A 92001-1510 BOLT,FLANGED,8X25,BLA 2
[Add to Picklist: 92001-1354]
92001B 92001-1354 BOLT,FLANGED,10X47 2
[Add to Picklist: 92028-1090]
92028 92028-1090 BUSHING,SHAFT CALIPER 1
[Add to Picklist: 92081-1229]
92081 92081-1229 SPRING,PAD 1

I would like to see what actually supports the inner pad. This caliper uses a different stile inner pad than mine. I would like to see the pad he is using and the support opposing the actual piston.

thanks for all the input. I am just home from work and had my tea(its 7pm now in Scotland). I am just about to go out for a ride and see if my mod has worked. Ceratinly seemed better last night on the short run I had.

The bike is a Z650 UK and is the F4 model. I believe that manufacture was stopped in 1983 but mine is registered in 1984

The diagram is the type of front caliper I have. I will post further photos tonight. Does not take long to pull the caliper.

I have pulled out the slider bolts and relubricated (slightly). I regularly check these for movement.

Thanks

Stewart

More photos

Bracket on bike. Caliper removed.


Caliper off bike.


View showing caliper with section showing area I ground down level.


Other side showing same thing


View facing piston.


Pads showing uneven wear. Lot better than prior to grinding level. Feels like it is bedding in tonight.



One of my bike 'cause it looks shiny!!

It looks to me like someone has buggered those calipers. I would get another set off of eBay.