1978 KZ1000 Project

The headlight ears and beauty rings will likely come off, and aftermarket ears and signals used, so not worried about the stack height of the ears.
Thinking of these bearings:

STEERING STEM BEARING KIT 22-1014 - Pete’s Superbike

What tires are some of you running on a KZ1000 1978?
Not a lot of choices at Pete's Suoerbikes where I've ordered many tires.

Thinking this for the front:

Bridgestone BT46 3.25-19 54H Front - Pete’s Superbike

And for the rear:

Bridgestone BT46 4.00-18 64H Rear - Pete’s Superbike

Both state Tubeless, but I imagine we can run tubes being a spoked wheel?
 

Yes, tubeless tires can be used with tubes.  And, I know some will disagree, but if you have cast wheels, early cast wheels did not have the safety ribs needed to run without tubes.  The ribs are to keep the beads seated in the event of low pressure and/or sudden side load or impact to the tire. You should use tubes if the ribs are not present.  A wheel designed for a tubeless application will be marked "tubeless".

Well then, You're a "custom" guy, didn't know that. No problem at all then. Just FYI, all those 22-1014's are built the same. Just the vendor that makes the difference in pricing. If you look on ebay they are everywhere for around 43USD with free shipping.

Took the front brake caliper off and apart for cleaning and new seals and dust covers.
The piston looks like it likely needs replacing.












 

Rob I've fixed your pics again !!!!!

I'd say that the piston is well and truly roached. 

If that is a KZ1000B, Brakecrafters have you covered.

brakecrafters.com/collections/1978-Kawasaki-1000-LTD-KZ1000B
 

No, she's an A model.
1978 KZ1000 A2.

I don't see a piston listed for that model at BrakeCrafters.


Had a go taking the front forks apart.
Managed to get the top caps and bottom Allen bolts loose, but now the bottom is just spinning.
I read, many times, about a special tool or home made version, to hold the damper inside from spinning.
What size is this "special tool"?

 

rstnick wrote:

I don't see a piston listed for that model at BrakeCrafters.
 

They may not be categorized correctly, but they should have them. It may require a phone call.

 

What size is this "special tool"?
 

I recommend a broom stick. Jam it down the tube and press against the top of the damping rod to add some friction.

TexasKZ wrote:

.... Brakecrafters have you covered.

brakecrafters.com/collections/1978-Kawasaki-1000-LTD-KZ1000B

 

Brakecrafters sells quality parts with good service, no doubt.  

But another cool option is phenolic pistons from Godffery's Garage.  

godfferysgarage.com/product/phenolic-bra...r-piston-kz-650-900/

Picture testing 

Crafters part # is BC4340CPSS. What they have assumed is the KZ900 1976-77 piston was the same, so it's listed as such. I ordered a couple, still have them, for a KZ900. But they are unsuitable for a KZ900 if you want to retain the 3 pieces that slip into the "cup" of piston. Sent them samples years ago thinking that they would resolve the machining but hasn't happened yet that i know of. We talk occasionally on the phone to resolve this. Steve is a cool cat and we talk about waay more then just this. Can't really tell from your photos but you should have a 43MM diameter piston. You have the "soft line" going into the caliper from the splitter which is correct for this year. But.. because ya never know what "might" have been changed, they have a 38MM piston style caliper too. They look identical from the outside but were used on the LTD 1000 with twin discs. Anyway, that first part number from Brakecrafters  is pretty much equivalent to the original 43048-009 Kawasaki part. 

I was reading about the Shindingen SH775 Regulator Rectifier combined unit upgrade for the older KZ/Z's.
Will something like these modern SH775s work?

Voltage Regulator Rectifier for 760cc Polaris 800 Ranger SH775 2011-2014 ATV | eBay