KZ 400 caliper swap?

Hey guys, i am working on a '78 KZ400A2 Deluxe. The front caliper was seized so i took it apart and the seals are toast. I haven't been able to find replacement seals for it. Just looking at the design of the caliper makes me think it would be a poor excuse for a front brake anyway, a visit to Clamshell city. This got me thinking that a caliper swap might be in order. Im curious if anybody has done this or has any suggestions for calipers that might work. The big issue would be clearing the spokes. it would be nice to stay with the 400 disk, but if that needs to go, so be it.

I have swapped a 440 caliper and forks on my "77.
It puts the caliper behind the fork. It requires a modified fender bracket.
I did see a H2 at the strip with a dual disc setup using flipped forks to
put the original calipers behind the forks. Might try the later caliper
and mount it up front. The bolt holes might not be the same.

I was hoping you would chime in Rex. I like the idea of the fork swap, it needs fork seals so i was going to have to get into the forks anyway. I imagine the 440 forks are a bit stiffer, so will help with me dwarfing the bike. Are they a direct fit? Can i use my existing wheel? As far as I can tell the disc mounting is the same as my other KZs. so i imagine disk would swap right over as well? thanks

I'll take some pics and measurements today.


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440 forks are a little longer. Mine are raised up in the triple clamps
about 3/4". The bolt holes are about 2 7/8" between centers. Just like
Most KZs. The 440 fender is made for a 19" wheel instead of an 18".


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Thanks for the info Rex. Im gonna get the 440 tubes in there and see how everything fits before i go full plunge with the caliper as well. I can't believe how generally cheap parts are for the 400/440 compared to the other KZ's. I just bought a mint set of forks for $50 shipped!

Rex, I got my 440 forks in the 400 trees and am trying to figure out how to get this to work. the 400 axle wont fit in the 440 fork, and It looks like you are using the 440 axle. Are you using 440 triple clamps too? as it sits the 400 clamps are too narrow to allow a brake to be mounted. there is 1/16th" on my setup between the disk and the fork tube; on yours it looks like you have a bit more room. what is the distance center to center of you fork tubes?

I'll get you an answer Friday evening.


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I had the same issue on my 76 KZ400. hard to believe the seals are no longer available. I was able to clean mine real good and re-use them. So far so good... There's also an EX500 swap out there I believe.

DoctoRot wrote: Rex, I got my 440 forks in the 400 trees and am trying to figure out how to get this to work. the 400 axle wont fit in the 440 fork, and It looks like you are using the 440 axle. Are you using 440 triple clamps too? as it sits the 400 clamps are too narrow to allow a brake to be mounted. there is 1/16th" on my setup between the disk and the fork tube; on yours it looks like you have a bit more room. what is the distance center to center of you fork tubes?

All my bikes with 33mm forks measure 5 3/4 in. between tubes.
That includes a 440 LTD, my "77 w/ 440 forks and a late "75 (8/75) frame.



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Your spacer on the disc side looks shorter.
Is the wheel centered between the forks?

So my forks are the same width. The wheel is not centered in the forks however. it is closer on the disk side. but there is no extra room on the speedo side. Is it possible i have a different speedo drive?