Kawasaki Piston

Motorcycle master cylinder Rebuild hard to do?

I have a 1984 Kawasaki ZN 1300 Voyager.The brake handle is loose enough to activate the rear brake light.Could this be caused by the front master cylinder needing to be rebuilt? How hard is this to do?

Hey John, haven't heard from you in a while. Ha! If you're talking about the front brakes, there's a piston stop that limits the distance the piston can move backwards, There could possibaly be crud between the piston and the stop keeping it from returning all the way or the spring that pushes the piston back could be broken. There's a plastic collar with two tabs that has to be depressed and removed, then the piston stop, piston and spring will come out.

If the rear master cylinder, there's a snap ring that holds the piston in place. Without looking, I can't remember if the rear brake light is operated by a mechanical linkage and spring or not. If so, simply adjusting that may cure the problem.

That's not so on the front because the switch is in a fixed position. If the brakes work fine otherwise, you might be able to take a small piece of metal and make a spacer and use silicone sealer to fasten it to the part of the lever that pushes onto the piston. That way it will reduce the amount of free play. I had to do that to make a different model spare brake lever work on my 1000.

If you need to tear into things, email me and I'll send you a copy of the parts diagram.

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