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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 07:44 #838512

  • Kozman011
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Hello gents!

I hope the weekend is finding everyone well. I have my front brake components completely removed from the bike. 1977 KX650 single disc. I have taken all the hoses off of the "T junction" and am wanting to refurbish the junction piece. I have done everything to get that brake switch off. Soaked it in penetrant for a week and even put the switch in a vise and torque on the junction with a wrench. Nothing. Not sure where else to go. I'm half tempted to cut it off and dig the threads out, which I'm OK with buying a new switch. Any thoughts? I'm sure a wise nugget of wisdom will pop up here! Thanks, as always!!

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 08:27 #838514

  • Rick H.
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Well Kozman, the only thing that pops into my head is perhaps whoever may have had the switch out before could have put some form of thread locker on it. Or it could just be some nasty form of corrosion that took place between the parts. Do you see any type of sealant on the joint area? You could as a last resort, before breaking something, try some heat on the junction block close to where the switch threads in. Try to only heat the junction block around the switch and see if that helps. I would use a propane torch for this and keep the flame low for control. Not sure what penetrant you used, but Kroil seems to work best for me. If you break the switch off I fear getting the broken end out of the junction would be a bummer. Good luck....
Rick H.
Rick H.

1977 Kawasaki KZ-1000A1

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 08:48 #838516

  • Kozman011
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Thanks Rick. I've been soaking it in PBBlaster. I did hit it with a propane torch previously, but that's before I had the vise installed. Maybe I'll give that a try again. I just need to go pick up some vise jaw protectors before I mess up that brake line junction. I don't recall seeing any thread locker, but I'm sure this switch is original.

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 09:04 #838518

  • martin_csr
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pbb didn't do very good in a couple of test floating around the internet. Kroil is supposed to be best, but Liquid Wrench penetrating spray lubricant is also good. I've had good luck with the LW. ..... Penetrant soak time & vibration w wood block & mallet can help.

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Last edit: by martin_csr.

Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 09:55 #838522

  • gd4now
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Did either of the banjo bolts create the same issue when removed from the 3 way junction? I would think the switch would not need to be any tighter. As others have indicated you may need to worry it with some type of penetrant , heat etc. As to jaws of the vice you can use soft pieces of wood. to protect the 3 way junction.
1977 KZ650 B1
Pods and Denco header


This is my Z

OLD KAW OWNERS SMILE ALOT

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 10:16 #838524

  • Nerdy
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Kozman011 wrote: I just need to go pick up some vise jaw protectors before I mess up that brake line junction.



You don't need anything special for that. Stop by any hardware store and pick up a piece of 1" or 1.25" angle aluminum: a 3ft piece will give you three sets of jaw protectors for a 6" vise. B)
1979 KZ400 Gifted to a couple of nephews
1967 Yamaha YCS1 Bonanza
1980 KZ440B
1981 Yamaha XT250H
1981 KZ440 LTD project bike
1981 GPz550
2013 Yamaha FZ6R

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 11:10 #838526

  • 73z1
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Bolt junction to the tree, use vise grips or pipe wrench.
I replaced a switch, it was very tight, was able to remove with vise grips.

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Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 13:31 #838531

  • 650ed
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Kozman011 wrote: Hello gents!

I hope the weekend is finding everyone well. I have my front brake components completely removed from the bike. 1977 KX650 single disc. I have taken all the hoses off of the "T junction" and am wanting to refurbish the junction piece. I have done everything to get that brake switch off. Soaked it in penetrant for a week and even put the switch in a vise and torque on the junction with a wrench. Nothing. Not sure where else to go. I'm half tempted to cut it off and dig the threads out, which I'm OK with buying a new switch. Any thoughts? I'm sure a wise nugget of wisdom will pop up here! Thanks, as always!!


Got any pictures of that "KX650" bike? I know there is a Kawasaki KLX650 (see below) and a KZ650, but I haven't seen a KX650. Ed

www.motorcyclespecs.co.za/model/kawasaki...saki_klx650%2093.htm
1977 KZ650-C1 Original Owner - Stock (with additional invisible FIAMM horn)

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Last edit: by 650ed.

Removing front brake switch. Or should I say "attempting" to remove!! 15 Nov 2020 19:40 #838539

  • z1kzonly
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Really? eBay.
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Removing front brake switch. Or should I say "attempting" to remove!! 16 Nov 2020 05:08 #838546

  • 73z1
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>>>>>>>>>>>>>>>>>>>>> Got any pictures of that "KX650" bike? I know there is a Kawasaki KLX650 (see below) and a KZ650, but I haven't seen a KX650. Ed
Z and X are near on keyboard.
77 to 83 KZ650 - en.wikipedia.org/wiki/Kawasaki_Z650

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Removing front brake switch. Or should I say "attempting" to remove!! 16 Nov 2020 10:47 #838557

  • z1kzonly
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At one time a few yrs. ago, I had a pile of about a dozen singles. I would have given you one . But I sold off most of my left overs. They are all the same I assume this is what you need?
Parts Godzilla:
This Kawasaki 43061-002 JOINT,THREE WAY Not Available fits the following models and components:

Kawasaki Motorcycle 1973 Z1 Z1 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1974 Z1-A Z1 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1977 KZ400-A1 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1978 KZ400-A2 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1976 KZ900-A4 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1978 KZ400-B1 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1979 KZ400-B2 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1975 Z1-B Z1 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1977 KZ900-A5 FRONT MASTER CYLINDER

Kawasaki Motorcycle 1977 KZ400-D4 FRONT MASTER CYLINDER ('76 -'77 KZ400 -

Kawasaki Motorcycle 1976 KZ400-D3 FRONT MASTER CYLINDER ('76 -'77 KZ400 -

Kawasaki Motorcycle 1975 KZ400-D FRONT MASTER CYLINDER ('76 -'77 KZ400 -

Kawasaki Motorcycle 1974 KZ400 FRONT MASTER CYLINDER ('76 -'77 KZ400 -

Kawasaki Motorcycle 1974 KZ400 FRONT MASTER CYLINDER ('74 -'75 KZ400/KZ

Kawasaki Motorcycle 1977 KZ400-D4 FRONT MASTER CYLINDER ('74 -'75 KZ400/KZ

Kawasaki Motorcycle 1976 KZ400-D3 FRONT MASTER CYLINDER ('74 -'75 KZ400/KZ

Kawasaki Motorcycle 1975 KZ400-D FRONT MASTER CYLINDER ('74 -'75 KZ400/KZ

Kawasaki Motorcycle 1974 Mach II - S3 FRONT MASTER CYLINDER (KH400-A3/A4)

Kawasaki Motorcycle 1977 KH400-A4 FRONT MASTER CYLINDER (KH400-A3/A4)

Kawasaki Motorcycle 1976 KH400-A3 FRONT MASTER CYLINDER (KH400-A3/A4)

Kawasaki Motorcycle 1978 KH400-A5 FRONT MASTER CYLINDER (KH400-A3/A4)

Kawasaki Motorcycle 1975 Mach II - S3-A FRONT MASTER CYLINDER (KH400-A3/A4)

Kawasaki Motorcycle 1976 KH400-A3 FRONT MASTER CYLINDER (KH400-A5)

Kawasaki Motorcycle 1978 KH400-A5 FRONT MASTER CYLINDER (KH400-A5)

Kawasaki Motorcycle 1975 Mach II - S3-A FRONT MASTER CYLINDER (KH400-A5)

Kawasaki Motorcycle 1977 KH400-A4 FRONT MASTER CYLINDER (KH400-A5)

Kawasaki Motorcycle 1974 Mach II - S3 FRONT MASTER CYLINDER (KH400-A5)

Kawasaki Motorcycle 1976 KH500-A8 FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1972 H1-C FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1975 H1-F FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1970 H1-A FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1971 H1-B FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1974 H1-E FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1973 H1-D FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1969 Mach III - H1 FRONT MASTER CYLINDER (KH500-A8)

Kawasaki Motorcycle 1979 KZ1000 - KZ1000-A3A FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1979 KZ1000 - KZ1000-A3 FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1978 KZ1000 - KZ1000-A2A FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1978 KZ1000 - KZ1000-A2 FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1977 KZ1000 - KZ1000-A1 FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1980 KZ1000 - KZ1000-A4 FRONT MASTER CYLINDER (KZ1000-A1)

Kawasaki Motorcycle 1979 KZ1000 - KZ1000-A3A FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1978 KZ1000 - KZ1000-A2 FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1977 KZ1000 - KZ1000-A1 FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1980 KZ1000 - KZ1000-A4 FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1979 KZ1000 - KZ1000-A3 FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1978 KZ1000 - KZ1000-A2A FRONT MASTER CYLINDER (KZ1000-A2/A2A)

Kawasaki Motorcycle 1978 KZ650-B2 FRONT MASTER CYLINDER (KZ650-B1)

Kawasaki Motorcycle 1978 KZ650-B2A FRONT MASTER CYLINDER (KZ650-B1)

Kawasaki Motorcycle 1979 KZ650-B3 FRONT MASTER CYLINDER (KZ650-B1)

Kawasaki Motorcycle 1977 KZ650-B1 FRONT MASTER CYLINDER (KZ650-B1)

Kawasaki Motorcycle 1979 KZ650-B3 FRONT MASTER CYLINDER (KZ650-B2/B2A/B3)

Kawasaki Motorcycle 1978 KZ650-B2A FRONT MASTER CYLINDER (KZ650-B2/B2A/B3)

Kawasaki Motorcycle 1978 KZ650-B2 FRONT MASTER CYLINDER (KZ650-B2/B2A/B3)

Kawasaki Motorcycle 1977 KZ650-B1 FRONT MASTER CYLINDER (KZ650-B2/B2A/B3)

Kawasaki Motorcycle 1979 KZ750-B4 FRONT MASTER CYLINDER (KZ750-B1/B2)

Kawasaki Motorcycle 1976 KZ750-B1 FRONT MASTER CYLINDER (KZ750-B1/B2)

Kawasaki Motorcycle 1977 KZ750-B2 FRONT MASTER CYLINDER (KZ750-B1/B2)

Kawasaki Motorcycle 1978 KZ750-B3 FRONT MASTER CYLINDER (KZ750-B1/B2)

Kawasaki Motorcycle 1978 KZ750-B3 FRONT MASTER CYLINDER (KZ750-B3/B4)

Kawasaki Motorcycle 1977 KZ750-B2 FRONT MASTER CYLINDER (KZ750-B3/B4)

Kawasaki Motorcycle 1979 KZ750-B4 FRONT MASTER CYLINDER (KZ750-B3/B4)

Kawasaki Motorcycle 1976 KZ750-B1 FRONT MASTER CYLINDER (KZ750-B3/B4)
Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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Removing front brake switch. Or should I say "attempting" to remove!! 16 Nov 2020 10:50 #838558

  • z1kzonly
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Livin in "CheektaVegas, NY
Still have a Kaw! 76 KZ900 Pro-Street.
Went thru 25 of these in 40 yrs.

And The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

Please Log in or Create an account to join the conversation.

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