1976 Kz 900 A4

just for the files. This a representation of 3 styles. The one void of anodizing is a 5/8 Tokico, exclusive to the 76LTD 900 that had duel disc's. Note the taller smooth, no ribbing on reservoir. The early 5/8 "optional accessory Z extra dicc kit master, also had a smooth reservoir but was shorter. It also had a stamped 5/8 font on top next to the lever pivot bolt. Then the ribbed style had two versions. Not much visual difference but the lever travel adjust threading was deeper on the early version and used a slotted adjust compared to the conventional bolt used on everyone thereafter. Zpedia at work, ha.

Well crap. I hope I didn’t rob the MC off my 900 LTD. It’s in the que to be restored at some point. Have to go digging tomorrow.

Asphalt900, did you remove the anodizing? I don’t remember them being natural aluminum color. Thank you for the detailed information.

I beadblasted the anodizing off it, it had that typical two-tone where the banjo bolt went. This one i could of had anodized but since the move just didn't have time. I send the crappy bore ones to Karps in California to SS re-sleeve and have the anodizing done in KCMO.

Mine was two tone, :laugh: I cleaned it up good scuffed it down and painted it with VHT caliper paint. Bore was good so I replaced the internals. Then picked the best cap I had.

That's the way to do it! Anodizing is a funny thing. All components have to be done at the same time otherwise color/sheen will vary. Oh wanted to thank-You for the Tripps Plating tip!! Talked to Justin last week, nice fella. He's going to get about 50lbs of hardware this week!

I just sent him a bunch. He’s Plating all the engine case bolts, re-chroming the trun signal stems, cam cover bolts, and exhaust clamps. I really like his chrome work. The rear rim turned out nice, and he did the headlight fork ears. Nice work. Actually I got his contact through Z1KZonly

I wonder why Kawasaki anodized the brake components rather than just painting them. It added a nice touch but must have been more expensive. My double disc Z1 came to me with a proper conversion, done in 1976 (according to the second disc date code) and the MC was badly faded. I had it painted because I didn't know of anyone who could restore it properly. Since then I've learned of one person in Oz who can do them.

Asphalt, you really know your stuff!

Thanks HMR! Actually it's just a by-product of seeing too many of these things, ha. I know of several places that anodize, it's become quite popular. The caliper holder was black chromate, because it was steel and aluminum got the anodize. I would assume they used it because brake fluid contamination possibilities. Anodize is affected by UV rays, that's why the masters look the way they do. Honda/Yamaha used it for the switchblocks and was quite durable, just the fade factor. Surprised Kawasaki didn't use on their switchblocks too? They started the paint thing for the trapezoidal master cylinders in 77-78 and they are always peeling around the cap. Those were also STEEL sleeved bores, terrible idea, always pitted. That's why they are soo expensive new. Tokico quit that thank goodness

Anodize is a chemical process. And with the tokico's, that steel 10mm insert for hose banjo bolt has to be removed.
Can't do aluminum with a piece of steel in it
Silicone dot 5 fixes the re-paint eating. Plus silicone does not absorb moisture.

Funny, as you guys are writing! I found an old picture from around 2012 (my old City garage house :laugh: ) with some Zinc work, and up in top left corner, a pile of Master cylinders. I bored 4 of them out on the lathe for 5/8" dual disc's. And caught Jeff Saunders, original Z1Ent. in Rochester, NY at the right time! He sold me 4 - Kaw Factory rebuild kits he had in stock for $38 a piece. I sold 1 bike with one, sold 2 on ebay and kept the last for myself.

And A-900 good for you on sending items to Tripp Plating! Let me know for sure when it gets there! I am going to pay them a visit. I'll take pics of your stuff! I need some chrome stripped! I have a lot of ugly Kaw engine covers with ugly corroded chrome. I learned last few to never throw out anymore Kaw parts for scrap!

Yes! It's going to be a relief to get some of this stuff done Z1. Like Matt mentioned, this hardware is like gold now, thankfully i just never tossed anything. Plus it's getting super difficult to source any of the pre-superseded stuff with the original stampings/dots or uniqueness. If there is a Belger Crain outside the building at Tripps it's just them dropping my stuff off, ha. Interesting You mention the 5/8 43072-002 into a former 1/2 master 43072-001, piston assy part numbers. I think years ago i took some measurements and something would of been out of whack to convert? I know the positioning of the relief and main holes are different so it would of put the primary cup in a compromising position, can't remember why i didn't do it? The trapezoidal master is the one with the steel sleeve/banjo threads, all the round ones were all aluminum. Thanks Again Z1 for sharing the info, MUCH Appreciated!! Going to be nice out today so a 6-pack, blast cabinet and that melodic hum of the compressor.

And BTW, i miss being able to chat with Jeff Saunders too. I think i have his number around here somewhere but be hardpressed to find it. Difficult to find a business that wants to talk on the phone anymore?

Marty, get progress photos for my latest batch. I just talked to Steve on the Wednesday before New Years Day. Thanks for the tip on the DOT 5 being all new lines and fresh MC and calipers I’m going to use it. Hat to see my work get ate up by nasty old school fluid.