Z1 900B Front Single Disc Brake Caliper Piston

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07 Oct 2015 18:02 #693720 by mardimus
So, I order the rebuild kit from Z1 Enterprises for the Single Disc Front Brake Caliper. I got everything sorted out besides the Piston Dust Boot. I cannot figure out for the life of me and searching this forum over and over on how to get the rubber boot around the metal slip that slides into the caliper groove.

I have the inserted the Piston Seal and then slid the piston into the caliper. Then what....

I tried inserting the metal ring into the caliper and then attached the dust boot but it wont go on. How does this work?

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08 Oct 2015 06:20 #693780 by z1kzonly
Replied by z1kzonly on topic Z1 900B Front Single Disc Brake Caliper Piston
First of all, clean that piston! smooth out all of those marks and gouges. You will tear your new boot.
This is what you do: put the seal on the piston, work it down,(use some brake assembly grease) as to have that lip go around the metal ring. Then work the piston through, while sliding it along the way. use a smooth, small (anything) like this popsicle stick.
As piston pushes into bore, the outer groove will catch the piston. And it's in and done.


Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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08 Oct 2015 06:24 #693781 by z1kzonly
Replied by z1kzonly on topic Z1 900B Front Single Disc Brake Caliper Piston
You basicly just slide the piston through the dust seal, after you catch it on the metal ring lip.
It might take a few tries.
But when you get it right, it will amaze you how easy it is.

Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

The following user(s) said Thank You: mardimus

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08 Oct 2015 06:26 - 08 Oct 2015 06:26 #693783 by mardimus
Replied by mardimus on topic Z1 900B Front Single Disc Brake Caliper Piston
Smoothed out the edges of the piston and will try to install again when I get home here in a few hours. Thanks again.
Last edit: 08 Oct 2015 06:26 by mardimus.

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08 Oct 2015 16:08 #693858 by mardimus
Replied by mardimus on topic Z1 900B Front Single Disc Brake Caliper Piston
Tiried to install this dust deal about 50 times. I'm struggling with the metal ring. So let me try and get this sorted out. If I have the piston in my hand, I then slide the rubber dust cover over the piston so that its flush at the base of the piston. Got that part.

I guess then the issue i have... does the metal ring then go on top outside the rubber dust boot and then you mash it all together or is the metal ring inside the dust seal and you try and slot the metal seal Into the groove? This is a pain in the ass.

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08 Oct 2015 16:13 #693860 by mardimus
Replied by mardimus on topic Z1 900B Front Single Disc Brake Caliper Piston
Here are a couple pics. I think I get it but the issue is that the seal pops out to easily. If the metal ring is in the inside of the seal and you have it at the base of the piston, when I slide the piston into the bore it starts to seat but nothing really catches. The seal just pops out the more I push it in. Where is the contact?


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08 Oct 2015 16:51 #693862 by mardimus
Replied by mardimus on topic Z1 900B Front Single Disc Brake Caliper Piston
Here are some more pics of the piston as It sits in the bore and then after it catches and releases.


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08 Oct 2015 17:25 #693867 by z1kzonly
Replied by z1kzonly on topic Z1 900B Front Single Disc Brake Caliper Piston
Hey, the metal ring should be in the caliper, always, tight hammered in. And stays there. And the thin part of the boot catches around that metal ring. Slip piston in and work it down, have either brake grease or brake fluid as a lubricant. Te thick 1/8 x 1/8 grove goes in the piston grove at the back, outside of piston. You have to keep the dust seal hooked around that metal ring as your sliding piston in.
Tap that ring in and leave it. maybe your seal is upside down?
Take a break, drink a beer. Try tommorow.

Livin in "CheektaVegas, NY
Went thru 25 of these in 40 yrs.
I SOLD OUT! THE KAW BARN IS EMPTY.
More room for The Old Girl, Harley 75 FLH Electra Glide,
Old faithful! Points ign. Bendix Orig. carb.
Starts everytime!

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