Brake Pad Replacement - KZ750

In short, I've been working on getting my project bike to pass inspection this quarantine. My latest works revolved around trying to get the brake up to snuff. The calipers came off fine and the old brakes, though rusted, came out easily enough. I ordered a new set from a local shop, and while they fit in the mountings, the brake pads are far too thick, nearly 3 times too thick in the front.

Does anyone have recommendations of where I can look to get pads that will actually fit? My manual asks for 3.35mm and 4.85mm for the front and back respectively. Every place I've looked, or that my local shop has asked at has either not had the pad lining listed, or is also far too thick.

I'm not sure I understood you correctly, but could it be that you just need to push the piston back into the calliper a bit to create more space?

Are you saying that the material on the front pads is 10mm thick, and 15mm thick on the rear?

Pics?

P.S. Putting the year and model info of your bike in the signature line of each post will make it easy for readers to know exactly which KZ750 you are asking about.

The usable thickness of the pad that actually wears against the rotor may be 3.35mm and 4.85mm when new, but the total pad thickness along with the metal backing is much more than that. I suspect calum has hit on the answer - push the piston all the way into the caliper before trying to fit it and the new pad back on the bike. Ed

calum wrote: I'm not sure I understood you correctly, but could it be that you just need to push the piston back into the calliper a bit to create more space?

This^

Did you push the caliper pistons back into the bore? And while you are at it It's advised to pop out the pistons entirely and check for pitting and to clean out all the grunge.

650ed wrote: The usable thickness of the pad that actually wears against the rotor may be 3.35mm and 4.85mm when new, but the total pad thickness along with the metal backing is much more than that. I suspect calum has hit on the answer - push the piston all the way into the caliper before trying to fit it and the new pad back on the bike. Ed

If I understand the op, the pads he got are three times that, but yes, the measurement is for the friction material only.

Yes, definitely go through the hydraulics if it has been more than four years since the last time, and definitely push the Pistons all the way in. If you have topped off the fluid recently, some may need to be removed.

What brake pads were installed? Part number?

Sorry, I should have clarified. The pads are able to sit in the caliper, however once there, there's too much friction material to fit over back over the disk as Texas said. The pistons are fully retracted. I did remove fluid to make sure the pistons weren't locked up either.

I'll try to get a picture of the issue when I can, unfortunately, I keep my bike in a friend's garage where it's safe.

Here's the brake pads attached. I don't know exactly where to get the parts number or find exactly where a listing of the friction material would be.

No eBay APP ID and/or Cert ID defined in Kunena configurationHeres a try... contact this seller and ask to measure his pads... or for the money just buy OEM pads...

Without knowing you specific bike, I found this photo of OEM pads. Next to it is a pamphlet that looks to identify different pistons possibly used in the caliber. Possible there are different pads relative to the piston configuration?

Those EBC pads are fine. If you can't get the caliper installed with those installed either the piston isn't pushed back properly or the caliper is binding on the sliding pins.

You have to give all caliper parts a good clean!!! This required a total disassembly of all parts!!!
You will be surprised what you will find inside the caliper, don´t trust the first view from oudside!!!