1982 KZ1300 rescue and rebuild

Yet another small project off my small table!

The front calipers were very dirty, inside out. The first thing I did was to remove as much dirt as I can, then spray it with a brake cleaner.







Then I started the disassembly.

I bead blasted the bodies before painting.

All painted and all the rest, including new rebuild kit and one new piston, ready for assembly.





Unfortunately, the ring holding the dust seal, didn't stay firm inside (here before cleaning just to show which one this is)



As seen in the first picture, they would slide out when moving pistons back and forth. I disassembled everything again.



As the last solution I decided to use high temperature Loctite to keep it in place. I wiped all excess to keep things clean and few days later I was sure it's cured and solid.

One piston was pitted, so I purchased a new one.



OEM on the left, replacement from Japan on the right.



The brake pads still look good. I measured the lining thickness.



The red arrow shows the service limit of 1 mm (the thickness of the stepped portion). Mine are where the green arrow points (2.5 mm) - well within the limit. I might later buy brand new pads, but for now these will work fine.

In this picture the pistons and dust seals are all in place. When assembling these parts I used the supplied with the rebuild kit red grease. These calipers will stay on shelf for some time, so I decided not to use any brake fluid for now. I scratched the edges from paint a bit using tools to pull out the pistons, but that's easily fixable.



The last photo - both calipers done and ready for mounting on the bike! Later that is. Right now on the shelf
My table is empty and ready for new project .

The inside of the fuel tank was really rusty. After 2 pounds of nails, 1 liter of vinegar, and occasional shaking for mechanical rust removal and wetting the inside with vinegar, it is starting to look good! Only one week.



I added the rest of the 4 liters container and taped it shut again. More baking and shaking



I will buy another 2 jugs and fill it completely up in a week and let it just sit this time. Most of the rust should be out and the tank ready for POR-15 treatment.
So far it's been a very easy process with great results.