my 2001 has developed a clunking noise...

[Jacobus De Bruyn]

Kawasaki Loquacious Rant-ers, Again about the rear brake. Dealer has no boots or seals, only a piston and a caliper boot, which is irrelevant at the moment. This brake seizure was NOT caused by negligence, lack of maintainance, old oil and the rest.- So come up with another excuse. Could it be that one of the washers around the Banjo bolts in the rubber line leaked air? Could that provoke seizure? So MC-guru Carlos checked the piston and the boot, and suggested some fine waterproof sandpaper, and cutting the boot to the appropriate size. So I have done that, and used some black sillicone on the boot. I had to cut abt 4 mm. to make it fit. It is back into the caliper, drying, and it all looks good, McGiver style. If you keep the brake lever in its right position, oil will dribble down of its own accord, and saves a hell of a lot of pumping. It all seems very obvious if you know, how come you know? Someone taught you, showed you. That s why I come on this site, to get knowledge. Unless you want to know about the single mother next door, who begged me for a date. Should I ask my wife for permission? I guess I ll soon be riding. Jacostarica.

[Kevin Powers]

You're living in paradise, riding year-round, and the neighbor women throw themselves at you. I'm here in MN where the ice just went off the lakes and if the neighbor lady threw herself at me she'd leave a crater in the lawn. No one ever said life was fair, eh? -- Kevin Powers White Bear Lake, MN On Thu, May 22, 2008 at 8:13 AM, Jacobus De Bruyn wrote:

> Kawasaki Loquacious Rant-ers, > Again about the rear brake. Dealer has no boots or > seals, only a piston and a caliper boot, which is > irrelevant at the moment. This brake seizure was NOT > caused by negligence, lack of maintainance, old oil > and the rest.- So come up with another excuse. > Could it be that one of the washers around the Banjo > bolts in the rubber line leaked air? Could that > provoke seizure? > > So MC-guru Carlos checked the piston and the boot, and > suggested some fine waterproof sandpaper, and cutting > the boot to the appropriate size. So I have done > that, and used some black sillicone on the boot. > I had to cut abt 4 mm. to make it fit. It is back > into the caliper, drying, and it all looks good, > McGiver style. If you keep the brake lever in its > right position, oil will dribble down of its own > accord, and saves a hell of a lot of pumping. > It all seems very obvious if you know, how come you > know? Someone taught you, showed you. That s why I > come on this site, to get knowledge. Unless you want > to know about the single mother next door, who begged > me for a date. Should I ask my wife for permission? > I guess I ll soon be riding. Jacostarica. > > >

[Non-text portions of this message have been removed]

[CA Stu]

--- In DSN_KLR650@yahoogroups.com, Jacobus De Bruyn wrote:

> > Kawasaki Loquacious Rant-ers, > Again about the rear brake. Dealer has no boots or > seals, only a piston and a caliper boot, which is > irrelevant at the moment. This brake seizure was NOT > caused by negligence, lack of maintainance, old oil > and the rest.- So come up with another excuse. > Could it be that one of the washers around the Banjo > bolts in the rubber line leaked air? Could that > provoke seizure? > > So MC-guru Carlos checked the piston and the boot, and > suggested some fine waterproof sandpaper, and cutting > the boot to the appropriate size. So I have done > that, and used some black sillicone on the boot. > I had to cut abt 4 mm. to make it fit. It is back > into the caliper, drying, and it all looks good, > McGiver style. If you keep the brake lever in its > right position, oil will dribble down of its own > accord, and saves a hell of a lot of pumping. > It all seems very obvious if you know, how come you > know? Someone taught you, showed you. That s why I > come on this site, to get knowledge. Unless you want > to know about the single mother next door, who begged > me for a date. Should I ask my wife for permission? > I guess I ll soon be riding. Jacostarica. >

Just because some hamburger suggested that solution doesn't make it a good idea. As far as cutting a seal and using silicone on it to make it fit, I don't think I'd put a lot of trust in that seal holding. http://www.bikebandit.com/assets/schematics/Kawasaki/1999KL650A13LCA_F2294.gif Are you referencing the part# 49068 or 43069 in the above diagram? I know that some seals do swell over time, but replacing them with a new one is the remedy. As far as bleeding the caliper and/or filling it initially, I use a Mityvac at home. I'd expect any decent mechanic or shop to have one, too. Haven't had to do it on the road yet. I wouldn't sweat too much about the rear brake not working, the front is way more important. And as far as what caused the seizure, I'm guessing dragging the brake by riding with your foot on the pedal. Have a fun trip. Thanks CA Stu

[D J]

Well I fixed the problem. It was the chain. It had a bent/sticking link I had never noticed before. Any a new chain & sprockets and I'm back on the road again. Thanks all. JD