KZ 550 master cylinder swap

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08 Jun 2014 22:06 #635877 by thoraxotool
KZ 550 master cylinder swap was created by thoraxotool
So the MC on my 550 died. I had a spare from an '83 550, but that cylinder is at a strange angle relative to my handlebars, so the lever juts out at an awkward angle. This will not do, but rebuild kits are seemingly impossible to find; everything is on back order. As such, I can't see rebuilding my old one as a viable option.

So, I'm thinking of hitting up Bent Bike and getting an MC from a Ninja 250 as I believe they are single caliper as well.
What I'm wondering is if any of you have done such a swap and how it turned out. Were there any unforeseen difficulties?
And finally, did any of you get a Ninja caliper to go with the MC?

Thanks for your help!

1982 KZ550 LTD

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09 Jun 2014 01:57 #635886 by Geeebeee
Replied by Geeebeee on topic KZ 550 master cylinder swap
No eBay APP ID and/or Cert ID defined in Kunena configurationI had similar issues with rebuild kit so ended up purchasing this unit complete with lever for my 1980 kz550 ltd. only thing is I have fitted flatter bars, works great.



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1980 kz550 c ltd.
1982 GPZ750R
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09 Jun 2014 06:26 - 09 Jun 2014 10:20 #635896 by martin_csr
Replied by martin_csr on topic KZ 550 master cylinder swap
Does your 550-Ltd have the stock handlebars or have they been replaced?
The stock mc has an angled mount to accommodate the original handlebars.

Does the Ninja mc have a mirror orifice? If I ever get around to replacing mine, I'll probably go with a new one from usa-motorcycles-inc --- similar to what Geeebeee linked --- the seller has several different units listed.

Stating the obvious, the OEM piston is NLA & K&L doesn't make one for the 550C. However, the 78 650B2 piston or its rubber parts may work. See page 2 of this topic for info & photos:
KZRider topic - My first project (550 LTD?)(pg 2)
Last edit: 09 Jun 2014 10:20 by martin_csr.

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11 Jun 2014 19:43 #636244 by thoraxotool
Replied by thoraxotool on topic KZ 550 master cylinder swap
Based on the overall stock-ness of there bike, I'm reasonably certain the handlebars are original. Aside from tires, there was NOTHING aftermarket on it as far as I could tell. Hell, the chain and sprockets were all original :p

I'll post a pic if that helps.

I've noticed that some ninja MCs are different than others in regard to mirror mounts, but I haven't found one yet. Seems the wrecking prefers to repair and resell ninjas rather then part them out.

But thanks for that link, I'm going to read it now.

1982 KZ550 LTD

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11 Jun 2014 20:47 - 11 Jun 2014 20:48 #636257 by martin_csr
Replied by martin_csr on topic KZ 550 master cylinder swap
If you install lower handlebars, the stock mc will not be level, so it may not be worth bothering with. If mine were shot, I would use that as an excuse to ditch it & get a new one, instead of rebuilding it. :)
Last edit: 11 Jun 2014 20:48 by martin_csr.

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