Rebuilding front brake caliper

[1340fxd]

I am rebuilding the front brake calipers on my Z1000 A2. The pistons went in fine with the newpiston seal

Now the puzzle. I have new dust seals - how do these fit? When I took the brakes apart there is this copper "L" section ring. My best guess is that I should fit this into the outer part of the rubber dust seal and use the now embedded copper ring to press into the cylinder to seal it.

Is that how it's done or am I way off the mark?

[Pigford]

1340fxd, spot on mate
I've just rebuilt the caliper on me RedZed, and it took me best part of 30 mins faffing around trying to get the dust seal on over the rim bit .........until I realised the 'L' shaped piece comes out & makes it easier to located the dust seal
Should have read the mainual first, as I've got both Haynes & Climer versions

[1340fxd]

Thanks Pigford - I've only got the Clymer manual and it goes all girlie about the brake caliper saying - take to genuine Kawasaki dealer, so no help there then!

[1340fxd]

Pigford - another question.

Have re-built caliper and am now fitting new EBC pads (FA33). The Clymer manual says that for 1973-1976 bikes, fit the shim. It then says what to do for a 1979 and later model - no mention of what to with 1977 and 1978 A1 & A2 models

Mine is a 1978 A2 and when I took the brakes out, there were no shims fitted behind the outboard pads (but I guess that means nothing other than the previous owner did not fit them!)

Do you know if A2 brakes should have the shim fitted or not please?

[Pigford]

Must admit, not too sure, but the shims are only to stop brake squeal, so if abscent, should not effect braking efficiency, or operation

[DogsbolloxofZ1B]

You probably know this but.. Make sure the metal hoses are tightened such that they don't exert any force on the calipers otherwise one of the pads will always be touching. The calipers float (or should do easily on the slide bolts) and if these hoses aren't secured in a neutral plane it can cause the pads to overheat/apply unecessary friction and even squeel a lot.