Replaced front shock ab. today - got a brake shock

Bought new pair from UK and refurbished them. Didn´t bother to think about the brake assembly but obviously that would have been a good idea! What do I do. My old pair is shot in every way but this way I cannot use the bike at all. will smaller calipers (correct ones) even fit onto my brake discs?

Got them from a GT550.

If you're going to swap fork up front (which is what I'm under the impression is what you're saying you did), the easiest route is to just swap the whole front end, wheel, brakes, and all. You really can't just slap a different kind of fork on and expect the wheel and brakes to fit properly. If you're trying to use most of the original Kaw parts, you'll have to have some fabricating done to get everything to mount up and line up as it should.

Also, what kind of bike is this on??? Put it in your signature so if you forget to put it in the post we can still see.

Well yes you pretty much said what I suspected to be the case. What I´d DO like to know is IF someone has done this before and can tell me if it´s dead in the water or if it´s doable.

Reverted back to old shocks Anyone wanna buy GT550 shocks in good condition? :S

What is the problem with the ones on there?

It´s completely different. Brake caliper fittings are smaller and closer together and KZ brake discs doesn´t fit GT550. And it´s just a mess. Nothing fits.

Here's some KZ400/500/550 brake info I've gathered:

Brake disks, and likely forks, depends on the year and location. There are a slew of different brake diameters for the 400/500/550 line.

The Kawasaki Factory service manual, uses the term "effective disk diameter" for it's measurements, which is not the actual O.D. measurement. From what I gather, "effective disk diameter" is measured from the center of the pad area.

From the factory service manual (red base manual 99924-1018-03):

1979 500B1 models:
Europe and Australia got dual front disks. They were 232mm.
Everywhere else got single disk. It was 250mm.
All had rear disk. It was 237mm.

1980 500B2 was the same 500B1.

The forks have bosses for calipers on both sides even if the bike only came with one brake. But the forks will be different from dual disk models because the disk sizes were different.

1980 400J1 model:
UK and West germany got dual disk 232mm.
Japan and elsewhere was single disk 250mm.
Rear drum.

1980 550A1 models:
Europe got dual disk 232mm.
Elsewhere single 250mm.
Rear drum.

1980 550C1 model:
European got dual disk 226mm.
Elsewhere single 236mm.
Rear drum.

1981 400J2
UK and West German dual disk 226mm.
Elsewhere single 236mm.
Rear drum.

1981 500B3:
All got dual disk 226mm.
Rear is 226mm.



1981 550A2 same as 400J2 single
1981 550C2 same as 400J2 single
1981 550B2 same as 500B3
1981 550D1 same as 500B3 (Actual O.D. is 260mm. Rear is 7mm thick, fronts are 5mm thick.)

The forks use different amounts of oil too.

kzrider.com/forum/2-engine/550226-oil-leak-need-help
here is some basic ideas as to repairing your forks seals.

Thank you but that is not the problem for me. The forks I have now, I have fitted new seals but it didn´t matter the chrome travel area is badly pitted. Also at some point and idiot has drilled a hole (4mm) beside the bottom screw (probably to make it wedged) and no sealent works down there anymore no matter what. I tried tapping it with a bolt and using sealent and copper washers, o-ring, rubber washers, heavy duty 80-s gasket maker etc. They are not worth the effort. That´s why I was happy to replace them with the refurbished forks I bought earlier this summer...only to be bummed by the caliper mounts etc. etc.
I can ride the bike as is but next summer I need new fork legs, have all winter to find new ones so.. although not that easy on eBay.

do those inners fit in the other outers?