Author Topic: Piston came out of front right caliper  (Read 294 times)

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Offline James99

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Piston came out of front right caliper
« on: June 05, 2019, 06:13:24 pm »
Hello all,
So I replaced my brake pads the other day. When i removed the front right caliper, the piston just fell out. Is that normal? Also, when i put everything back together the bike is hard to move in neutral. As always, thanks in advance for any help.

Offline batboy

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Re: Piston came out of front right caliper
« Reply #1 on: June 05, 2019, 07:08:10 pm »
Early C10 or later version? Did the piston have a dust seal that is in good condition? You might need new seals at the very least.
1988 Kawasaki Concours ZG1000 - Ninja Edition
Bike has the usual accessories and modifications

Offline works4me

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Re: Piston came out of front right caliper
« Reply #2 on: June 05, 2019, 07:13:21 pm »
This might be a stupid question but did the actual metal piston fall out
or just the plastic dampener?

Offline James99

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Re: Piston came out of front right caliper
« Reply #3 on: June 05, 2019, 07:56:20 pm »
It is a 99 concours.
The actual piston came out.
To answer the other question, I dont know what the dust seal is. Sorry

Offline batboy

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Re: Piston came out of front right caliper
« Reply #4 on: June 05, 2019, 09:07:10 pm »
I was hoping someone with more Concours experience would jump in. I've worked on lots of brake, but never the front brakes of a Connie. Let me quote the service manual:

* * *

Caliper Assemble Notes:

Apply brake fluid to the outside of the piston and the fluid seal, and push the piston into the cylinder by hand. Take care that neither the cylinder nor the piston skirt get scratched.

Install the dust seal around the piston. Check that the dust seal is properly fitted into the grooves in the piston and caliper.

* * *

If you're saying, "What seal?" Then I suspect that's the problem. You're missing the seal.
1988 Kawasaki Concours ZG1000 - Ninja Edition
Bike has the usual accessories and modifications

Offline Stasch

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Re: Piston came out of front right caliper
« Reply #5 on: June 06, 2019, 12:08:59 pm »
Quote
Install the dust seal around the piston. Check that the dust seal is properly fitted into the grooves in the piston and caliper.

The only grooves are in the caliper 'cylinders'.  The pistons are as smooth as a baby's bottom.

If there weren't any seals at all, fluid would have been leaking out unless the system was dry.
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He IS a racer, hence the forward lean!!  by: Mettler1