How to install dust seal on brake caliper

Hey folks the rear brake caliper on the KZ750 was getting stuck on me so I ordered a brake calper rebuild kit. I took it apart and cleaned it. The inside seal was a breeze to install but the dust seal is proven to be a pain in the --- to install. I used plenty of fluid to lube it and still cant get the sob to slide in.:blush:

How does the darn thing go? LOL
Any help is apprieciated.

Try soaking it in very hot water to make it more flexible.
The same goes for carb boots.

You're talking about the dust seal that goes around the brake piston and has to fit around a collar, right?

If so I just had the same problem rebuilding the front calipers on my 650 - I found that the easiest way is to pry out the collar with a broad flat-tipped screwdriver, mount the seal on the collar then press the assembled collar and seal back in.

Be careful when prying out the collar, you don't want to deform it, just go easy and work around it and it should come right out.

Yes the rear brake caliper. I got the old one off but having difficulties installing the new one.

So install the dust seal on the piston first and then install the piston on the caliper? I tried it but cannot get the dust seal to seat in the inside of the caliper groove.

I'll give it a try after runnng it trough hot water.

my trick with rubber parts is starting fluid. spray some on and the boot or what ever is slick as snot for about 30 seconds then when it evaps it is dry as before with no residue. works super slick on hand grips, I dont even use glue, just spray on and they slide right up then grip super when the fluid is gone. works in reverse too, slide a philips screw driver in from the end and squirt some juice in, pull the driver and twist pops right off.

No, I mean pry out the collar that makes the groove - the pics show one of my spare 650 front calipers, but yours should be similar in construction:

Easy does it:

Collar is out:

Install the seal on the collar - old throwaway seal but it serves the purpose:

Install the piston:

Slide the seal and collar over the piston and press the collar back in:

OnkelB that was an awesome response. I just wanted to say great job man!

+2 Karma points for Onkel