Caliper Conversions

Tokico Conversion

Convert LH to RH

Convert LH to RH II

Convert LH to RH (video)

Included here are several ideas on caliper conversions.  Click on the pic for full view.

It is recommended to use a 5/8 bore master cylinder for any dual disc setup.  However, a 9/16 with steel braided lines may suffice.  H1/2 optional dual disc was fitted with 5/8, while 9/16 was standard.  The 5/8 cylinder is stamped "5/8" at the lever.  The KZ650-C (dual disc) was also fitted with a 5/8, identical in appearance the the H cylinder.  Rick Brett offers 5/8 master cylinders.

The H1 is fitted with a dual outlet junction block at the lower triple tree.  The H2 & KH must have a dual block added or use a banjo bolt that will accommodate two lines.

Note that caliper mounting lugs on KH forks are wider apart than on H1/2, i.e., Z caliper won't fit KH, KZ caliper won't fit H1/2.

The LH H1/2 caliper mount plate can be machined to eliminate the lower boss and used with a spacer for a RH fit.  The line will enter from the front unless adapters are used to reverse the line and bleeder.  Use of the Z caliper eliminates this line problem. 

The KZ 650 discs (at least some of them) are 5mm thick vs. 7.5mm on the H.  They are a bolt on to the KH wheel (4 lug).  This drastically reduces weight but always use new pads for safety as it is under recommended minimum thickness (5.5mm) for stock calipers.



Click pics above for larger images

Installation Video for adapter above

Adapter in pdf format

Adapter in DXF format

400 Conversion

KH500 Conversion

Economy Conversion

EX 500 caliper list

Additional pics and info can be found here.

KH500 Upgrade
KH500 forks, KH wheel, GPZ900 caliper, Z650 disc, GPZ900 m/cyl.
Bolts straight on, but the pads overlap the disc, so you need a small amount trimming off.