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.

Kawasaki Intruder Invader Drifter 440 78 80 Piston Ring
Kawasaki Intruder Invader Drifter 440 78 80 Piston Ring
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Kawasaki Sno Jet Yamaha 440 motor MAG side JUG HEAD PISTON PIN BEARING
Kawasaki Sno Jet Yamaha 440 motor MAG side JUG HEAD PISTON PIN BEARING
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Wiseco Piston Kit Kawasaki Intruder 440 78 80 15
Wiseco Piston Kit Kawasaki Intruder 440 78 80 15
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Wiseco Piston Kit Kawasaki Invader 440 81 82 STD
Wiseco Piston Kit Kawasaki Invader 440 81 82 STD
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Wiseco Piston Kawasaki KX80
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vitage wiseco arctic cat kawasaki wiseco 400 +020 piston set free ship 2083p2
vitage wiseco arctic cat kawasaki wiseco 400 +020 piston set free ship 2083p2
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vintage kawasaki wiseco 2082p2 piston +020 arctic cat john deere free ship
vintage kawasaki wiseco 2082p2 piston +020 arctic cat john deere free ship
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Wiseco Piston 6820mm John Deere Trailfire Kawasaki 440 Drifter More Model 79 82
Wiseco Piston 6820mm John Deere Trailfire Kawasaki 440 Drifter More Model 79 82
$41.38
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Wiseco 6225mm Piston Kawasaki Mirage SkiDoo 377 Engine More Models 1979 2006
Wiseco 6225mm Piston Kawasaki Mirage SkiDoo 377 Engine More Models 1979 2006
$67.38
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KAWASAKI PISTON PIN  NEEDLE BEARING SET 59146 3002 NOS OEM
KAWASAKI PISTON PIN NEEDLE BEARING SET 59146 3002 NOS OEM
$18.92
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Kawasaki Articat Piston pin set PN 59146 509
Kawasaki Articat Piston pin set PN 59146 509
$21.95
Time Remaining: 2d 10h 19m
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1972 EXT ARCTIC CAT T1A 400 R1A KAWASAKI PISTON NO RING NEW OLD STOCK ITEM
1972 EXT ARCTIC CAT T1A 400 R1A KAWASAKI PISTON NO RING NEW OLD STOCK ITEM
$120.00
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ARCTIC CAT  KAWASAKI 340CC TWIN CYLINDER PISTON RINGS GENUINE KAWASAKI
ARCTIC CAT KAWASAKI 340CC TWIN CYLINDER PISTON RINGS GENUINE KAWASAKI
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JOHN DEERE  KAWASAKI 440CC INVADER LTD LIQUIFIRE PISTON WITH RINGS LEMANS BRAND
JOHN DEERE KAWASAKI 440CC INVADER LTD LIQUIFIRE PISTON WITH RINGS LEMANS BRAND
$120.00
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Wiseco Piston Kit Kawasaki Drifter 440 78 80 1
Wiseco Piston Kit Kawasaki Drifter 440 78 80 1
$86.88
Time Remaining: 3d 11h 16m
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Wiseco Piston Kit Kawasaki Intruder 440 78 80 1
Wiseco Piston Kit Kawasaki Intruder 440 78 80 1
$86.88
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Wiseco Piston Kit Kawasaki Drifter 440 78 80 15
Wiseco Piston Kit Kawasaki Drifter 440 78 80 15
$83.32
Time Remaining: 3d 11h 16m
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Wiseco Piston Kit Kawasaki Drifter 440 81 82 STD
Wiseco Piston Kit Kawasaki Drifter 440 81 82 STD
$76.21
Time Remaining: 3d 11h 37m
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Wiseco 6225mm Piston Kawasaki Mirage SkiDoo 377 Engine More Models 1979 2006
Wiseco 6225mm Piston Kawasaki Mirage SkiDoo 377 Engine More Models 1979 2006
$73.23
Time Remaining: 3d 13h 10m
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ARCTIC CAT 440 KAWASAKI PISTON CHROME RINGS SET OF 2 RINGS T1 SERIES 1971 1975
ARCTIC CAT 440 KAWASAKI PISTON CHROME RINGS SET OF 2 RINGS T1 SERIES 1971 1975
$25.55
Time Remaining: 4d 8h
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Arctic Cat Kawasaki Lynx EXT 290 292 Twin KT440 3 Triple Piston Ring Set 555mm
Arctic Cat Kawasaki Lynx EXT 290 292 Twin KT440 3 Triple Piston Ring Set 555mm
$24.60
Time Remaining: 4d 9h 58m
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LeMans Kawasaki Snowmoble Piston 8072
LeMans Kawasaki Snowmoble Piston 8072
$25.00
Time Remaining: 4d 10h 44m
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WISECO 3189KD snowmobile Polaris 700 Arctic Cat Kawasaki piston ring set NEW
WISECO 3189KD snowmobile Polaris 700 Arctic Cat Kawasaki piston ring set NEW
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Wiseco Piston Kit 6950 mm Kawasaki Intruder 440 1978 1980
Wiseco Piston Kit 6950 mm Kawasaki Intruder 440 1978 1980
$94.72
Time Remaining: 5d 10h 10m
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Wiseco Piston Kit 6950 mm Kawasaki Drifter 440 1978 1980
Wiseco Piston Kit 6950 mm Kawasaki Drifter 440 1978 1980
$94.72
Time Remaining: 5d 10h 10m
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Wiseco Piston Kit 6950 mm Kawasaki Invader 440 1978 1980
Wiseco Piston Kit 6950 mm Kawasaki Invader 440 1978 1980
$94.72
Time Remaining: 5d 10h 10m
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Wiseco Kawasaki ZR600 STD BORE Piston 2427M07800
Wiseco Kawasaki ZR600 STD BORE Piston 2427M07800
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Time Remaining: 5d 10h 52m
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1983 2003 Kawasaki KX60 4295 CC Namura Piston Kit Kawasaki Std
1983 2003 Kawasaki KX60 4295 CC Namura Piston Kit Kawasaki Std
$51.26
Time Remaining: 5d 11h 23m
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ARCTIC CAT KAWASAKI 440CC PISTON RINGS AFTERMARKET STILL IN PACKAGE NOS ITEM
ARCTIC CAT KAWASAKI 440CC PISTON RINGS AFTERMARKET STILL IN PACKAGE NOS ITEM
$38.50
Time Remaining: 5d 11h 24m
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ARCTIC CAT KAWASAKI 340 PISTON RINGS WITH TOP L RING NEW OLD STOCK IN THE BOX
ARCTIC CAT KAWASAKI 340 PISTON RINGS WITH TOP L RING NEW OLD STOCK IN THE BOX
$30.00
Time Remaining: 5d 11h 47m
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Wiseco Piston Kit 6800 mm Kawasaki Intruder 440 1981
Wiseco Piston Kit 6800 mm Kawasaki Intruder 440 1981
$76.21
Time Remaining: 5d 13h 10m
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Wiseco Piston Kit 6800 mm Kawasaki Drifter 440 1981 1982
Wiseco Piston Kit 6800 mm Kawasaki Drifter 440 1981 1982
$76.21
Time Remaining: 5d 13h 10m
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Wiseco Piston Kit 6800 mm Kawasaki Invader 440 1981 1982
Wiseco Piston Kit 6800 mm Kawasaki Invader 440 1981 1982
$76.21
Time Remaining: 5d 13h 10m
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KAWASAKI 399CC TWIN CYL STANDARD BORE POWERDOME PISTON WITH RING NEW OLD STOCK
KAWASAKI 399CC TWIN CYL STANDARD BORE POWERDOME PISTON WITH RING NEW OLD STOCK
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1995 2003 Kawasaki KEF300 LAKOTA 7645 CC Namura Piston Kit 020
1995 2003 Kawasaki KEF300 LAKOTA 7645 CC Namura Piston Kit 020
$80.96
Time Remaining: 5d 15h 16m
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2006 2009 Kawasaki KX250F 7697 CC Namura Piston Kit c Series
2006 2009 Kawasaki KX250F 7697 CC Namura Piston Kit c Series
$150.26
Time Remaining: 5d 15h 16m
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1988 2002 Kawasaki KLF220 BAYOU 6747 CC Namura Piston Kit 020
1988 2002 Kawasaki KLF220 BAYOU 6747 CC Namura Piston Kit 020
$72.86
Time Remaining: 5d 15h 16m
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1988 1990 Kawasaki KX80 4845 CC Namura Piston Kit Kawasaki 020
1988 1990 Kawasaki KX80 4845 CC Namura Piston Kit Kawasaki 020
$71.96
Time Remaining: 5d 15h 16m
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2006 2009 Kawasaki KX250F 7695 CC Namura Piston Kit Std
2006 2009 Kawasaki KX250F 7695 CC Namura Piston Kit Std
$150.26
Time Remaining: 5d 15h 16m
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1987 2005 Kawasaki KLR250 7395 CC Namura Piston Kit Std
1987 2005 Kawasaki KLR250 7395 CC Namura Piston Kit Std
$100.76
Time Remaining: 5d 15h 17m
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1987 2004 Kawasaki KSF250 MOJAVE 7395 CC Namura Piston Kit Std
1987 2004 Kawasaki KSF250 MOJAVE 7395 CC Namura Piston Kit Std
$100.76
Time Remaining: 5d 15h 17m
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2001 2002 Kawasaki KX125 5394 CC Namura Piston Kit Kawasaki Std
2001 2002 Kawasaki KX125 5394 CC Namura Piston Kit Kawasaki Std
$68.36
Time Remaining: 5d 15h 17m
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2001 2013 Kawasaki KX85 4845 CC Namura Piston Kit Kawasaki Std
2001 2013 Kawasaki KX85 4845 CC Namura Piston Kit Kawasaki Std
$72.86
Time Remaining: 5d 15h 17m
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1995 2003 Kawasaki KEF300 LAKOTA 7695 CC Namura Piston Kit 040
1995 2003 Kawasaki KEF300 LAKOTA 7695 CC Namura Piston Kit 040
$80.96
Time Remaining: 5d 15h 17m
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1986 2004 Kawasaki KLF300 BAYOU 7695 CC Namura Piston Kit 040
1986 2004 Kawasaki KLF300 BAYOU 7695 CC Namura Piston Kit 040
$80.96
Time Remaining: 5d 15h 17m
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1998 2000 Kawasaki KX 125 5394 CC Namura Piston Kit Kawasaki Std
1998 2000 Kawasaki KX 125 5394 CC Namura Piston Kit Kawasaki Std
$65.66
Time Remaining: 5d 15h 18m
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2001 2013 Kawasaki KX85 4847 CC Namura Piston Kit c Series
2001 2013 Kawasaki KX85 4847 CC Namura Piston Kit c Series
$72.86
Time Remaining: 5d 15h 18m
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1988 2002 Kawasaki KLF220 BAYOU 6797 CC Namura Piston Kit 040
1988 2002 Kawasaki KLF220 BAYOU 6797 CC Namura Piston Kit 040
$72.86
Time Remaining: 5d 15h 18m
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1986 2004 Kawasaki KLF300 BAYOU 7645 CC Namura Piston Kit 020
1986 2004 Kawasaki KLF300 BAYOU 7645 CC Namura Piston Kit 020
$80.96
Time Remaining: 5d 15h 18m
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1995 2003 Kawasaki KEF300 LAKOTA 7745 CC Namura Piston Kit 7750mm
1995 2003 Kawasaki KEF300 LAKOTA 7745 CC Namura Piston Kit 7750mm
$80.96
Time Remaining: 5d 15h 39m
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2005 2008 Kawasaki KX250 6636 CC Namura Piston Kit
2005 2008 Kawasaki KX250 6636 CC Namura Piston Kit
$80.96
Time Remaining: 5d 15h 39m
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1988 2002 Kawasaki KLF220 BAYOU 6847 CC Namura Piston Kit 6850mm
1988 2002 Kawasaki KLF220 BAYOU 6847 CC Namura Piston Kit 6850mm
$72.86
Time Remaining: 5d 15h 39m
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1992 2003 Kawasaki KX250 6735 CC Namura Piston Kit 6740mm
1992 2003 Kawasaki KX250 6735 CC Namura Piston Kit 6740mm
$78.26
Time Remaining: 5d 15h 39m
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2000 2013 Kawasaki KX65 4496 CC Namura Piston Kit 4496mm
2000 2013 Kawasaki KX65 4496 CC Namura Piston Kit 4496mm
$51.26
Time Remaining: 5d 15h 39m
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2000 2013 Kawasaki KX65 4546 CC Namura Piston Kit 4546mm
2000 2013 Kawasaki KX65 4546 CC Namura Piston Kit 4546mm
$51.26
Time Remaining: 5d 15h 39m
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2002 2003 Kawasaki KVF650 PRARIE 7996 CC Namura Piston Rings Std
2002 2003 Kawasaki KVF650 PRARIE 7996 CC Namura Piston Rings Std
$19.76
Time Remaining: 5d 15h 39m
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2000 2013 Kawasaki KX65 4595 CC Namura Piston Kit 4595mm
2000 2013 Kawasaki KX65 4595 CC Namura Piston Kit 4595mm
$51.26
Time Remaining: 5d 15h 39m
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95 09  11 13 Kawasaki KX100 5244 CC Namura Piston Kit 525mm
95 09 11 13 Kawasaki KX100 5244 CC Namura Piston Kit 525mm
$70.16
Time Remaining: 5d 15h 39m
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1988 1990 Kawasaki KX80 4797 CC Namura Piston Kit 4797mm
1988 1990 Kawasaki KX80 4797 CC Namura Piston Kit 4797mm
$71.96
Time Remaining: 5d 15h 39m
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1998 2000 Kawasaki KX 125 5395 CC Piston Kit
1998 2000 Kawasaki KX 125 5395 CC Piston Kit
$65.66
Time Remaining: 5d 15h 41m
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1998 2000 Kawasaki KX 125 5396 CC Piston Kit
1998 2000 Kawasaki KX 125 5396 CC Piston Kit
$65.66
Time Remaining: 5d 15h 48m
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2001 2002 Kawasaki KX125 5395 CC Piston Kit
2001 2002 Kawasaki KX125 5395 CC Piston Kit
$68.36
Time Remaining: 5d 15h 48m
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2003 2006 Kawasaki KFX 400 9046 CC Namura Piston Kit 020
2003 2006 Kawasaki KFX 400 9046 CC Namura Piston Kit 020
$118.76
Time Remaining: 5d 21h 53m
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2003 2006 Kawasaki KLX 400 8996 CC Namura Piston Kit Std
2003 2006 Kawasaki KLX 400 8996 CC Namura Piston Kit Std
$118.76
Time Remaining: 5d 21h 53m
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1987 2005 Kawasaki KLR250 7395 CC Namura Piston Rings Std
1987 2005 Kawasaki KLR250 7395 CC Namura Piston Rings Std
$20.66
Time Remaining: 5d 21h 55m
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1987 2005 Kawasaki KLR250 7445 CC Namura Piston Rings 020
1987 2005 Kawasaki KLR250 7445 CC Namura Piston Rings 020
$20.66
Time Remaining: 5d 21h 59m
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2003 2006 Kawasaki KFX 400 8996 CC Namura Piston Kit Std
2003 2006 Kawasaki KFX 400 8996 CC Namura Piston Kit Std
$118.76
Time Remaining: 5d 21h 59m
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1987 2004 Kawasaki KSF250 MOJAVE 7395 CC Namura Piston Rings Std
1987 2004 Kawasaki KSF250 MOJAVE 7395 CC Namura Piston Rings Std
$20.66
Time Remaining: 5d 21h 59m
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1988 2002 Kawasaki KLF220 BAYOU 6697 CC Namura Piston Rings Std
1988 2002 Kawasaki KLF220 BAYOU 6697 CC Namura Piston Rings Std
$17.06
Time Remaining: 5d 22h 1m
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1999 2003 Kawasaki KVF300 PRAIRIE 7595 CC Namura Piston Rings Std
1999 2003 Kawasaki KVF300 PRAIRIE 7595 CC Namura Piston Rings Std
$17.96
Time Remaining: 5d 22h 1m
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1988 2002 Kawasaki KLF220 BAYOU 6747 CC Namura Piston Rings 020
1988 2002 Kawasaki KLF220 BAYOU 6747 CC Namura Piston Rings 020
$17.06
Time Remaining: 5d 22h 1m
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1987 2004 Kawasaki KSF250 MOJAVE 7445 CC Namura Piston Rings 020
1987 2004 Kawasaki KSF250 MOJAVE 7445 CC Namura Piston Rings 020
$20.66
Time Remaining: 5d 22h 1m
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2003 2006 Kawasaki KFX 400 9146 CC Namura Piston Kit 9150mm
2003 2006 Kawasaki KFX 400 9146 CC Namura Piston Kit 9150mm
$118.76
Time Remaining: 5d 23h 44m
Buy It Now for only: $118.76

2005 2008 Kawasaki KX250 6637 CC Namura Piston Ring Set 664mm
2005 2008 Kawasaki KX250 6637 CC Namura Piston Ring Set 664mm
$13.46
Time Remaining: 5d 23h 44m
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1999 2003 Kawasaki KVF300 PRAIRIE 7745 CC Namura Piston Ring Set7750mm
1999 2003 Kawasaki KVF300 PRAIRIE 7745 CC Namura Piston Ring Set7750mm
$17.96
Time Remaining: 5d 23h 44m
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1986 2004 Kawasaki KLF300 BAYOU 7745 CC Namura Piston Ring Set7750mm
1986 2004 Kawasaki KLF300 BAYOU 7745 CC Namura Piston Ring Set7750mm
$17.96
Time Remaining: 5d 23h 49m
Buy It Now for only: $17.96