How to on brakes

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02 Jun 2010 07:39 #372803 by Genros
How to on brakes was created by Genros
Anyone have a full "how to" on brakes for a 77kz900? bike has been sitting for like ten years and brakes are sticking in back and front is barely working

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  • TeK9iNe
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  • What did you do!?!
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02 Jun 2010 11:18 #372849 by TeK9iNe
Replied by TeK9iNe on topic How to on brakes
I would look for an origional Kaw service manual on eBay or someplace.

Or...

Remove the calipers and drain everything.

Dissasemble the calipers. To get the pistons out of the calipers, you place them in a doubled plastic/or fabric bag, and apply some compressed air to the brake line hole.
Carefully, and slowly till the piston pops out.

Then you just clean up the caliper bore and piston lightly with some scotchbrite pad.
Use a brake rebuild kit, and reinstall everything with clean brake fluid.

bench test your assemblies with compressed air before installing. The piston should slide out slowly with just low pressure, and slide back in by hand.

GL!

B)

Motorcycle Shop Owner/Operator

79 Kawie Z1000 LTD
81 Kawie Z1000 CSR
83 Honda VT750C A
85 Kawie GPZ900 A2
86 Zukie GS1150 EG
93 Yamie XV1100 E
Lucky to have rolled many old bikes through my doors ;)

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02 Jun 2010 13:46 #372864 by TexasKZ
Replied by TexasKZ on topic How to on brakes
If they are so bad that they are sticking, I'd add to TeK9iNe's advice to rebuild the master cylinder and flush the lines of any crud and moisture. How do the flexible lines look? If heavily cracked, I'd consider new ones. Brakes should not be done half-a...sed.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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02 Jun 2010 13:47 #372865 by TexasKZ
Replied by TexasKZ on topic How to on brakes
BIG +1 on the factory shop manual. It's worth its weight in scotch.

1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough

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02 Jun 2010 17:33 #372916 by JMKZHI
Replied by JMKZHI on topic How to on brakes
If the lines are original or old, maybe look into replacing them. It's fairly common for folks to get stainless steel braided lines - the kind w the outer protective plastic sheathing will protect your bike from scratches. I installed Goodridge lines & fittings. If you've changed the handlebars or the upper line is otherwise too long, now would be the time to get the correct size.

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02 Jun 2010 17:52 #372919 by Patton
Replied by Patton on topic How to on brakes
Z1E carries a large variety of brake hoses, different types, sizes, etc.

Click > Z1E Brake Hoses

Good Luck! :)

1973 Z1
KZ900 LTD

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04 Jun 2010 08:10 #373369 by Genros
Replied by Genros on topic How to on brakes
Thanks guys, i picked up a manual and going to tinker this weekend. Im dying to get the bike on the road. It screams but feel like a stupid twelve year old on his first crash and burn when trying to stop. (i was a little to impatient to feel the power)

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