brake rebuild kit question

Hey guys, I bought two of this brake rebuild kit from z1enterprises for my 78 650 d1 (SR): www.z1enterprises.com/ItemDetails.aspx?i...f1300&item=KL32-1289

It's pretty strange. Even though it's listed for my model the piston seal is too big and the o-rings and dust boots make it so tight that the bolt can't slide easily through the holes. This means that the brake can't be applied since it's essentially stuck and unable to move due to the tension on the bolts. Even after hitting it with wd-40 I still had to force the bolt through. What gives?? A bit more info.. I bought this 38mm piston seal earlier, before deciding to just get the whole rebuild kit and this one DOES fit: www.z1enterprises.com/ItemDetails.aspx?i...X900&item=43049-1097

Did I get the wrong kit and do I need to order the o-rings and dust boots all individually?

Just noticed it says it contains the 42mm caliper seal, so that explains that.. but still doesn't explain the o-rings and dust seals being so tight. Those are part numbers 43052-005 and 43053-006. Maybe the ones in the kit are not perfect fit?

gc - i always buy genuine brake stuff - they always fit

I thought there were no genuine options for these classic bikes. One time I went in to a Kawasaki dealer to get parts and they didn't have a single thing I needed on a long list. Do you have a link to order from?

Sorry mate - you are right - very poor on Kawasakis part
This is usually where i look to get an idea - guess these are same as what you have :
www.bikebandit.com/oem-parts/1978-kawasa...-us/o/m3239#sch82449

Yours is a D1 model ?

Yes it's the D1. By the way.. over $6 for an o-ring? Damn. If anyone knows what I'm doing wrong here I'd much appreciate a hint.

Take a look at the link below and the part numbers below the diagram. Which parts are you missing? Ed

www.dealercostparts.com/pages/oemparts#/...0-D1-1978/070053D-10

Hi Ed, I'm not missing anything. If I can use the parts diagram as reference, the o-rings (# 12) and dust covers (#11) make it so tight that I cannot easily slide the bolts (#2) through the caliper and pad holder. If I remove the o-rings and covers I can easily slide the bolt through. Previously, with the old worn out rings and covers I could move the pad holder back and forth along the bolts no problem. But now, once I install everything the pad holder is immovable.

I don't know why you used WD-40 on anything, that stuff is only good for displacing water and removing gummy labels from containers?? Did you lubricate the caliper bolts (#2) with Poly Butyl Cuprysil (PBC) as instructed in the Kawasaki Service Manual? Ed

I actually used PB Blaster on the bolts to lube them because that's what was next to me at the moment. But I just read the whole brake chapter in my Clymer manual and I don't see any mention of needing to lube the bolts. It just says to apply a light coat of brake lube to the back of the pads and piston. Is PBC what I need?

First - toss the Clymer manual and buy the correct Kawasaki Service Manual for your particular bike's year / model. Be sure to get the correct one as there are significant differences between models. Also, PB Blaster is not a lubricant and is not a good substitute for the proper grease. It is a penetrating oil intended for use in loosening stuck / corroded fasteners. The manual calls for PBC. If you cannot find it I believe a proper grease that is meant to be used on disk brake caliper pins would be a reasonable substitute.

Here's text from the Kawasaki Service Manual:

I use Permatex Ultra Disk Brake grease in the little packets. I think it might be a molybdenum disulfide synthetic lubricant. Some say the stuff swells buna-s rubber, but I've never had any problems with it. Another product is Castrol Red Rubber grease.

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