Kawasaki Sportsbike Riders Club - Australia - Online Forum

Am i right in thining that all i need to purchase to overhaul the calipers are the caliper seals and the dust seals??

Bike is a 1996 ZX6R and i hae absolutely no braking pressure whatsoever. Tried bleeding but the pistons don't move.

I did it on my 96 ZX6 a couple of weeks ago. If everything goes to plan, it is not a very hard task. But it can be tricky to get the pistons out. If they are stuck it will be very difficult to get them out.

Mike wrote:I did it on my 96 ZX6 a couple of weeks ago. If everything goes to plan, it is not a very hard task. But it can be tricky to get the pistons out. If they are stuck it will be very difficult to get them out.

Cheers bud.

Were the seals all you needed???

Going to have a crack at it on boxing day.

Mike wrote:I did it on my 96 ZX6 a couple of weeks ago. If everything goes to plan, it is not a very hard task. But it can be tricky to get the pistons out. If they are stuck it will be very difficult to get them out.

If you don't mind the mess you can pump them out

I used an air compressor and aimed the pistons into a big pile of rags (they come out fast). Easy

waynemorgan wrote:I used an air compressor and aimed the pistons into a big pile of rags (they come out fast). Easy

Spot on wayne , take the calipers off & carefully blow the pistons out, I tend to keep pressure on the fisrt one that moves so the other is forced out first, If you get one out & the other wont budge then block off the hole in the other & try the compressed air again.
Once you have them out clean & check the piston surface for wear replace the seals & make sure you grease the piston surface with high temp grease, they should work a treat after that

it may be the master cylinder, when the seals go the fluid goes past the piston instead of pushing the caliper pistons out

wullieb1 wrote:

Mike wrote:I did it on my 96 ZX6 a couple of weeks ago. If everything goes to plan, it is not a very hard task. But it can be tricky to get the pistons out. If they are stuck it will be very difficult to get them out.

Cheers bud.

Were the seals all you needed???

Going to have a crack at it on boxing day.

There are 8 dust seals and 8 boot seals. Also, there are 4 caliper seals that go between the fluid galleries where the calipers meet. I forgot about getting these the first time I did it.

Don't crack the Calipers apart, then you wont need the extra seals

Mike wrote:

wullieb1 wrote:

Mike wrote:I did it on my 96 ZX6 a couple of weeks ago. If everything goes to plan, it is not a very hard task. But it can be tricky to get the pistons out. If they are stuck it will be very difficult to get them out.

Cheers bud.

Were the seals all you needed???

Going to have a crack at it on boxing day.

There are 8 dust seals and 8 boot seals. Also, there are 4 caliper seals that go between the fluid galleries where the calipers meet. I forgot about getting these the first time I did it.

Nice one Mike.

WIll phone Kwaka tomorrow and see if they have them in stock if not they can order them for me.

Got the master cylinder kit from Kwaka today and fitted it. The old piston and spring literaly fell out when i tipped it over lol.

Got it all back together and can't get no fukn pressure whatsover on the lever.

My brother-in-law has recommended back bleeding it so a trip to Supercheap tomorrow to get some bits and bobs for that.

I will get this fecker back on the road. The coont has been sitting for a couple of months now and i need a ride on it lol.

Damn how did you get your kit so fast? Mine is on backorder and won't be in till 3-4 Jan

who did you get it from?

thats a bugga, hope it works for you.................. paging QLD members that could HELP out?

put some rubber hose on the bleed nipple, and suck it through. then one you have fluid coming out the bottom you will be able to get some pressure.

MrWasabi wrote:Damn how did you get your kit so fast? Mine is on backorder and won't be in till 3-4 Jan

who did you get it from?

Got it from the dealer m8.

Could had a couple of kits if i needed them.

If you want i can go get the kit and post it to ya and you can bank transfer the cost over.

Wattie wrote:put some rubber hose on the bleed nipple, and suck it through. then one you have fluid coming out the bottom you will be able to get some pressure.

Thats the plan tomorrow m8. Need to go get some hose first though lol.

robracer wrote: thats a bugga, hope it works for you.................. paging QLD members that could HELP out?

All part of the learning process. Apparently someone said it was good fun lol. I do beg to differ when i just wanna ride the fecker