Brake Caliper Rebuild Kit Installation

  • 79MKII
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06 Nov 2014 10:30 #653047 by 79MKII
Hello All,

Just having a brain cramp and the manual isn't much help. I can't remember how the caliper bracket dust seals were mounted....should they go all of the way down on both sides?? Please see photo below. Thanks



The Kaw List:
Current: 79 KZ1000 A3 MKII, 78 KZ1000 A2, 78 KZ1000 Z1-R, 78 KZ650 SR, 80 KE175
Former: 03 KLX400SR, 99 ZRX1000, 82 KZ750 LTD, 80 KZ1000 A4 MKII, 80 KZ1000 LTD, 78 KZ1000 A2, 74 H-2 750 Triple, 78 KL250
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06 Nov 2014 10:35 - 06 Nov 2014 10:37 #653048 by 79MKII
Replied by 79MKII on topic Brake Caliper Rebuild Kit Installation
Kits and parts diagrams call for same boots for all four locations. The RH side boots are not seated as shown above....not sure if that being loose at the end will matter? it seems that the face of the boot might be better placed flat against the face of the spacer as it is on the LH side....thoughts?

The Kaw List:
Current: 79 KZ1000 A3 MKII, 78 KZ1000 A2, 78 KZ1000 Z1-R, 78 KZ650 SR, 80 KE175
Former: 03 KLX400SR, 99 ZRX1000, 82 KZ750 LTD, 80 KZ1000 A4 MKII, 80 KZ1000 LTD, 78 KZ1000 A2, 74 H-2 750 Triple, 78 KL250
Last edit: 06 Nov 2014 10:37 by 79MKII.

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06 Nov 2014 15:48 #653091 by spdygon
Replied by spdygon on topic Brake Caliper Rebuild Kit Installation
Don't mean to high jack you post but I was about to ask the same question.
Have all this rubber pieces left...calipers only had the piston seal and dust boot.
The bolt caps would not stay in place.

1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project

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06 Nov 2014 15:51 - 06 Nov 2014 15:54 #653092 by spdygon
Replied by spdygon on topic Brake Caliper Rebuild Kit Installation

When installing the bolt...as I would put pressure the cap would come off the bracket.
So I left them off.

1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project
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Last edit: 06 Nov 2014 15:54 by spdygon.

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06 Nov 2014 19:39 #653107 by spdygon
Replied by spdygon on topic Brake Caliper Rebuild Kit Installation
79mk2.......

just finish my kit install....yes that how they go. did not know the o-rings went inside the bracket hole into a ring channel.
took a while to bleed to brake lines....suck 1.5hours

1982 GS1000sz Katana ( #15...17K Miles)
1982 GS1000sz Katana ( # 297....7100k Miles)
1978 Kz1000 Z1R. 10K Miles1
1978 kz1000 z1r 27k miles
1977 KZ 1000 A ( Project ) 54K Miles
1976 Kz900A4 (Red)21K miles
1976 Kz900A4 ( Red)7500 miles
1974 Z1 900 project

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  • 79MKII
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07 Nov 2014 07:33 #653137 by 79MKII
Replied by 79MKII on topic Brake Caliper Rebuild Kit Installation

spdygon wrote: 79mk2.......

just finish my kit install....yes that how they go. did not know the o-rings went inside the bracket hole into a ring channel.
took a while to bleed to brake lines....suck 1.5hours


I had a hard time remembering where the o-rings went too! It's been a while since I've done a total rebuild. I'm not looking forward to bleeding the system....that part always sucks.

The Kaw List:
Current: 79 KZ1000 A3 MKII, 78 KZ1000 A2, 78 KZ1000 Z1-R, 78 KZ650 SR, 80 KE175
Former: 03 KLX400SR, 99 ZRX1000, 82 KZ750 LTD, 80 KZ1000 A4 MKII, 80 KZ1000 LTD, 78 KZ1000 A2, 74 H-2 750 Triple, 78 KL250

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20 Feb 2024 20:30 #895474 by Naxos
Replied by Naxos on topic Brake Caliper Rebuild Kit Installation
Any tips on getting this bracket on the caliper with the dust seals seated properly? I can’t seem to get them in without them coming off the bracket. 

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25 Feb 2024 16:47 - 25 Feb 2024 16:50 #895592 by rstnick
Replied by rstnick on topic Brake Caliper Rebuild Kit Installation
Lubrication!
Some grease to hold the boots on, and slide into the caliper.
I used a wheel bearing grease, on the bolts/sliders.
Carefully slide the bolts in, making sure the boots don't get distorted.

I recall the 650's to be tricky, but managed.
 

Rob
CANADA

Need a key for your Kawasaki? PM me

1978 KZ650 C2, 130K kms, Delkevic ex, EI, CVK32, PMC easy clutch, ATK fork brace, steering damper, Progressive Suspension, braced swingarm, ZRX shocks, 18" Z1R front wheel.
2000 ZRX1100
2011 Ninja 250R - Wife's
2005 z750s
Last edit: 25 Feb 2024 16:50 by rstnick.

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