KZ1100 front brake problem

Bike is 1982 KZ1100 shaftie with dual front discs.
Just rebuilt master cylndr and calipers and all new teflon/stainless lines.
Problem: Right calip[er does not release smoothly, binds when brake is released.
It appears to be a full floating caliper, but the bolt it 'floats' on has a rubber coating in one area that appears to be swollen, causing the caliper to not release.

Does anyone have any comments or suggestions on how to fix?

FloridaBiker wrote:

Bike is 1982 KZ1100 shaftie with dual front discs.
Just rebuilt master cylndr and calipers and all new teflon/stainless lines.
Problem: Right calip[er does not release smoothly, binds when brake is released.
It appears to be a full floating caliper, but the bolt it 'floats' on has a rubber coating in one area that appears to be swollen, causing the caliper to not release.

Does anyone have any comments or suggestions on how to fix?

Am wondering if the rubber coating is actually a melted dust cover or o-ring. Believe it's time to take another look inside the caliper.

quote]

Am wondering if the rubber coating is actually a melted dust cover or o-ring. Believe it's time to take another look inside the caliper. [/quote]

No rubber coating huh?
I will remove the 'condom' and see how that works.
Thanks!

The rubber coating appears to be part of the design.
One of the bolts does have a rubber sleeve fitted to it.
Is this stock or some aftermarket thing?

I welcome any comments or suggestions.
Thanks guys.

Post edited by: FloridaBiker, at: 2007/07/03 07:03

Just to be clear I am including a picture of the bracket this bolt came from.

Post edited by: FloridaBiker, at: 2007/07/03 07:06

The kawasaki.com diagram shows two caliper shafts, #43045 plain smooth, and #43045A fitted with a "bushing" #92028.

Perhaps the covering is the "bushing?"

Must defer to others more familiar with this particular design.

Will try to post the diagram.

Patton: Thanks for the picture.
What I found was that sediment buildup (technical term: crud) was keeping everything from sliding freely.
I removed the bushing, cleaned the bolts, applied disc brake grease (non harmful to the rubber)and everything works great.
It's a lot faster now!

I had a similar problem on my 1982 J.

It appears (after everything else was eliminated) that the plastic sleeves can swell causing in my case the caliper to retract too far from the disc once pressure was removed. That was my problem anyway.

I had a devil of a job pulling the lower pins out of the bracket showing they were binding in their holes. Replacing these was cheap parts were available and its as good as new now.

I have refrained from greasing them as anti seize compound I believe caused the swelling