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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2003 2006 Kawasaki KLX 400 9146 CC Namura Piston Kit 9150mm
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1992 2003 Kawasaki KX250 6785 CC Namura Piston Kit 6790mm
1992 2003 Kawasaki KX250 6785 CC Namura Piston Kit 6790mm
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2005 2008 Kawasaki KX250 6635 CC Namura Piston Kit 664mm
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2000 2013 Kawasaki KX65 4496 CC Namura Piston Kit 4496mm
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1988 1990 Kawasaki KX80 4796 CC Namura Piston Kit 4796mm
1988 1990 Kawasaki KX80 4796 CC Namura Piston Kit 4796mm
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2000 2013 Kawasaki KX65 4546 CC Namura Piston Kit 4546mm
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2000 2013 Kawasaki KX65 4595 CC Namura Piston Kit 4595mm
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1992 2003 Kawasaki KX250 6685 CC Namura Piston Kit 6690mm
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1988 1990 Kawasaki KX80 4797 CC Namura Piston Kit 4797mm
1988 1990 Kawasaki KX80 4797 CC Namura Piston Kit 4797mm
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$14.06
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2005 2008 Kawasaki KX250 6637 CC Namura Piston Kit
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2003 2006 Kawasaki KLX 400 8998 CC Namura Piston Kit
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1998 2000 Kawasaki KX 125 5395 CC Piston Kit
1998 2000 Kawasaki KX 125 5395 CC Piston Kit
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2003 2006 Kawasaki KLX 400 9146 CC Namura Piston Ring Set9150mm
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1992 2003 Kawasaki KX250 6636 CC Namura Piston Kit
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