Kawi2strokes.com Forum

Hi. Does anyone have some information in overhauling KH500 disc brakes. ? I am trying to remove the inner piston but it does not seem to come all the way out ? The fluid nossle is shot so I cannot pump any fluid through it to push it out. Is there some sort of trick to getting the piston out?

Alo I have a twin disk. Can a normal brake holder be reversed to attach to teh front fork leg ?

Thanks for the site its a big help. Steve

Compressed air will shift a tight piston - but please think of the safety aspects of this first!!!! ( it is actually compressed air being released that does the work!!)

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"One day, your life will flash before your eyes. Make sure it's worth watching." : anon.

+1 to compressed air. You will need about 120 psi usually. I use a spray gun with a rubber cone nozzle on it. The nozzle will seal tightly in the bleed hole screw if you push hard. Use plenty of rags. The piston will pop out along with fluid. Don't get your fingers smashed and don't get sprayed in the face with fluid.

If that doesn't work I go to phase III. Everyone cringes when I tell them this but it works. I put the caliper in the oven on 200 degrees F. Let it stay in there for about 20 minutes. Then I take it out to the garage and do the air trick. I have gotten some really stuck pistons out this way. The aluminum is fine up to about 300 degrees F. Above that aluminum begins to anneal and lose some strength.

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Rotortech
Indianapolis
1974 S3

If you can fit a grease nipple (zerk?) with an adapter you can pump it out with a grease gun. Surprisingly high pressures can be obtained and its relatively safe, if messy

That won't be a big problem, as the KH500 has the same caliper as Z type 4's, they came with twin disks, so find you're self a right hand one (there must be plenty around on e-bay) and you're ready to go.

Nigel,

Good technique. I forgot about it. Others who have welders have just welded the proper screw to a zerk fitting and they are ready to go. I haven't use this method but it should make a lot of pressure. Brakes are messy anyway so a little more grease shouldn't hurt.

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Rotortech
Indianapolis
1974 S3

I used this method with success on an RD:

http://www.hvccycle.com/brakes-removal.html

Terry