Warning - K & L Master Cylinder Kit

[Nessism]

Bought a K & L master cylinder kit and some brake caliper rebuild kits from Z1 Enterprises for my '82 850 refresh project.

Installed the master cylinder kit and first of all noticed the rubber boot is too tall - extends up above the portion of the piston where the lever contacts (not good for long life of the boot since the lever may pinch it). After bleeding the master it didn't feel properly firm and the lever would stick after the bike sat for a few hours. Finally gave up and pulled the master back apart noticing the piston has scuff marks on the metal portion where it apparently was binding on the internal bore of the master cylinder. Not good. My guess is that the piston is too large and needs more clearance.

The caliper kits seem ok but the seals have a more coarse surface finish than the OE parts which are shinny and super smooth for rubber parts. Serviceable but not as nice as the OE parts in my opinion.

Going to call Z1 on Monday and try to return the master cylinder kit. Going to stay all OE for brake rebuild kits from now on.

[chef1366]

I only use the OEM for the M/C rebuilds but just rebuilt my rear caliper with a K&L and it was perfect. :-D

[psyguy]

not good news.
i have k&l m/c rebuild kit in the drawer and was planning on doing it someday.
thanks for the warning though, that way if anything goes wrong i won't need to scratch my head or bother you guys here to help me out.

[Nessism]

Measured the diameter of the piston and it appears to be in spec. The part must be bowed in some way.

When bleeding the brakes with the K&L master kit installed there was a squeak noise that I dismissed as coming from the lever itself. With hind sight I've realized that the squeak was the metal to metal interference with that piston in there. Hope the cylinder bore is not scored up too bad. Put the stock piston back in since it was in good shape and it seems to work fine...fingers crossed.

[hikermikem]

Well yours is certainly a timely post. I am planning on rebuilding my front M/C & both calipers in the next few weeks on my '82 1100G. I too was going to use the K&L kits from Z1, but after reading your post I think I'll stick with OEM parts.

Is there a concenus on where the best place to purchase these parts from? Flatout seems to offer the best prices, but I've had shipping issues with them (meaning, "where the hell are my parts?"). I hate to use my local dealer, as they always seem to stare at me with that, " there's the guy with the old bike we know nothing about - I wish he'd stop buggin' us & just buy a new one" look.

I've just received my 2 new Speigler front SS brakelines, so I'm starting to get excited about installing them. I don't know if they are ultimately the best choice, but I liked the customer service I received when I spoke with them on the phone - didn't get the same "warm fuzzy" from the places I called selling Galfer lines. Plus, the Speigler fittings seemed to be available in more angles.

Ridin' season is just around the corner here in CT !!

mike

[Nessism]

Based on the recommendation of a member here I recently placed an order with motogrid.com. Prices are similar to Flat Out but shipping was much faster. Only negative is the shipping price was high. I usually go with Bike Bandit but motogrid is worth considering - look at total package price.

[hikermikem]

Thanks for the input - I'll check 'em out.

Good luck with your brake M/C, kinda sucks when your best laid plans don't really work out.

[Nessism]

Good luck with your brake M/C, kinda sucks when your best laid plans don't really work out.

Thanks.

The new (old) bike is in pretty good shape, just some age rot. Brake fluid was brown which means (typically) chunkies on the inside...thus my reason for ordering the new seals. Old seals were in fine shape but the exterior boots, exposed to the weather, were a little rough.

I usually go with OE brake parts but I just love Z1 so the K&L parts were ordered.

For brake lines there's an Earl's store in my area so I typically build my own. Most of the lines use a straight banjo on one end and a sideways bent banjo on the other. The shop crimped on the straight banjos and I cut the lines to length and installed the bent banjos myself. Many people are paranoid about installing brake line ends but honestly, it's dead easy. The old lines get scale on the inside thus replacing them is mandatory in my opinion. New lines firm up the lever feel which is an added bonus.\\/

[Killer2600]

I have to say my experience with the K&L front m/c rebuild kit has been quite the opposite, just as good as OEM without reusing any original parts.

[Nessism]

I have to say my experience with the K&L front m/c rebuild kit has been quite the opposite, just as good as OEM without reusing any original parts.

Want another kit? Only used for a few hours since it wouldn't work in my master cylinder.
BTW, the OE kits are complete and don't require reusing any original parts either.

[rapidray]

Hey Ness, did you HONE the M/C before reassembly? Ray.

[Nessism]

Hey Ness, did you HONE the M/C before reassembly? Ray.

No hone, not necessary, even harmful, if the bore is clean. Bores are almost mirror finish when new and honing only damages that finish.