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KZ650C rear disk brake
- sflesch94
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29 Apr 2023 17:56 - 29 Apr 2023 17:57 #883971
by sflesch94
KZ650C rear disk brake was created by sflesch94
Hi everyone, the service manual I have only covers rear drum brakes. I have rear disk on my kz650. Wondering if there is a trick to removing and installing the rear caliper. Trying to slide it over the rotor and rear brake mount is very difficult, and I feel like I am damaging the rubber seals on the caliper mount holes.
Last edit: 29 Apr 2023 17:57 by sflesch94. Reason: Picture
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- TexasKZ
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29 Apr 2023 18:38 #883973
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic KZ650C rear disk brake
Did you remove the axle first?
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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29 Apr 2023 18:44 #883974
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic KZ650C rear disk brake
Perhaps the 650D rear disc brake is the same. If so, this manual may help.
www.kzrider.com/modules/ServiceManuals/K...l%20KZ650%201981.pdf
www.kzrider.com/modules/ServiceManuals/K...l%20KZ650%201981.pdf
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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29 Apr 2023 18:45 #883975
by sflesch94
Replied by sflesch94 on topic KZ650C rear disk brake
Yes I had the wheel off, but I removed the caliper alone, not the caliper mounting bracket. Now putting it back is giving me issues.
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- TexasKZ
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29 Apr 2023 18:49 #883976
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic KZ650C rear disk brake
According to Partzilla, the 650C and D rear brake assembly has the same part number, so the manual linked above should have the correct rear brake info for your bike.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
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29 Apr 2023 18:52 - 30 Apr 2023 06:01 #883977
by TexasKZ
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Replied by TexasKZ on topic KZ650C rear disk brake
Ok, thanks. I hope the manual has a solution for you. I suspect one of the 650 owners here will be along shortly with some sage advice .Yes I had the wheel off, but I removed the caliper alone, not the caliper mounting bracket. Now putting it back is giving me issues.
1982 KZ1000 LTD parts donor
1981 KZ1000 LTD awaiting resurrection
2000 ZRX1100 not ridden enough
Last edit: 30 Apr 2023 06:01 by TexasKZ.
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30 Apr 2023 01:18 #883983
by Wookie58
Replied by Wookie58 on topic KZ650C rear disk brake
Are the pistons nad pads pushed back fully - if so there should be no resistance sliding the calliper over the disc. Have you replaced any parts and if so what with ?
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30 Apr 2023 07:18 - 30 Apr 2023 07:24 #883988
by Moose1800
You need to remove the caliper and bracket as one piece, with it off the bike then remove the pads then you can remove the caliper from the bracket.
Installing the caliper on the bracket can be trickey with those 4 rubber dust seals make sure you have new ones on hand and don't get any grease on the inside of the dust seals it's a tight fit and if I remember correctly the caliper will only go on the bracket in one direction and the bracket needs to be off the bike when reinstalling the caliper back on the bracket.
New dust seals can be had at brakecrafters.com
Replied by Moose1800 on topic KZ650C rear disk brake
Hi everyone, the service manual I have only covers rear drum brakes. I have rear disk on my kz650. Wondering if there is a trick to removing and installing the rear caliper. Trying to slide it over the rotor and rear brake mount is very difficult, and I feel like I am damaging the rubber seals on the caliper mount holes.
You need to remove the caliper and bracket as one piece, with it off the bike then remove the pads then you can remove the caliper from the bracket.
Installing the caliper on the bracket can be trickey with those 4 rubber dust seals make sure you have new ones on hand and don't get any grease on the inside of the dust seals it's a tight fit and if I remember correctly the caliper will only go on the bracket in one direction and the bracket needs to be off the bike when reinstalling the caliper back on the bracket.
New dust seals can be had at brakecrafters.com
Last edit: 30 Apr 2023 07:24 by Moose1800.
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30 Apr 2023 07:45 #883992
by sflesch94
Replied by sflesch94 on topic KZ650C rear disk brake
Yeah I didn’t remove the mounting bracket. I got the caliper off somehow though. Here is where I am at. I don’t really see how the bracket being off the bike will be different, the part I’m having trouble clearing is those dust boots. Maybe I need to coat them with a little grease so the caliper slides over easier.
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30 Apr 2023 08:08 - 30 Apr 2023 08:11 #883997
by Moose1800
With the mounting bracket off the bike you will be able to see the dust seals go into place, it's very easy to tear the dust seals when installing the caliper on the bracket or they fall off before going into place and you won't be able to see it. It's no big deal to remove the bracket your almost there. Their isn't much holding the dust seals on the bracket and it can be frustrating trying to get the caliper on the bracket even with the bracket off the bike. You can try it your way you might get lucky but good luck.
Also if you use grease you need to use brake grease and use it sparingly and grease the caliper bolts to.
Replied by Moose1800 on topic KZ650C rear disk brake
Yeah I didn’t remove the mounting bracket. I got the caliper off somehow though. Here is where I am at. I don’t really see how the bracket being off the bike will be different, the part I’m having trouble clearing is those dust boots. Maybe I need to coat them with a little grease so the caliper slides over easier.
With the mounting bracket off the bike you will be able to see the dust seals go into place, it's very easy to tear the dust seals when installing the caliper on the bracket or they fall off before going into place and you won't be able to see it. It's no big deal to remove the bracket your almost there. Their isn't much holding the dust seals on the bracket and it can be frustrating trying to get the caliper on the bracket even with the bracket off the bike. You can try it your way you might get lucky but good luck.
Also if you use grease you need to use brake grease and use it sparingly and grease the caliper bolts to.
Last edit: 30 Apr 2023 08:11 by Moose1800.
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30 Apr 2023 10:13 #884000
by Mikaw
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
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Replied by Mikaw on topic KZ650C rear disk brake
Moose1800 has the correct advice. Pull the axle and remove the bracket. Assemble the caliper and install as a unit.
1976 KZ 900 A4 kzrider.com/forum/11-projects/613548-1976-kz-900-a4
1976 KZ 900 B1 LTD
1978 KZ 1000 B2 LTD
1980 KZ 750 E1
Kowledge Speaks, But Wisdom Listens.
Jimi Hendrix.
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30 Apr 2023 17:11 #884020
by Kelly E
The Rust Bros. Garage Collection
1974 Honda CB 550 K0
1975 Honda CB 400F Super Sport
1977 Kawasaki KZ 1000 LTD
1980 Suzuki GS 1100E
1982 Honda CB 900F Super Sport
1983 Honda CB 1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1990 Moto Guzzi 1000
1994 Kawasaki ZG 1000 Concours
And more
Replied by Kelly E on topic KZ650C rear disk brake
My early(#442) 77' KZ 1000LTD has the same rear brake setup as your bike. The manual says it is different but I know it's original. It seems like the mounting bracket only goes in from one end of the caliper or it knocks the slider pin boots off. It took me a few tries to get it and I tore a boot in the process, order a couple extras.
The Rust Bros. Garage Collection
1974 Honda CB 550 K0
1975 Honda CB 400F Super Sport
1977 Kawasaki KZ 1000 LTD
1980 Suzuki GS 1100E
1982 Honda CB 900F Super Sport
1983 Honda CB 1100F
1984 Honda Sabre 700
1984 Honda Interceptor 1000
1990 Moto Guzzi 1000
1994 Kawasaki ZG 1000 Concours
And more
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