1982 KZ1300 rescue and rebuild

Rear master cylinder before and after.

There are a few small scratches as I had to play with it after painting to fit everything, but that's an easy fix with touch ups. I mentioned it before and I have to mention it again - to my surprise many of the surfaces on this bike are not exactly a perfect finish! Kawasaki seemed not to pay too much attention to quality surface finishing, many surfaces are what I would call rather crude and welds look ugly. I am not going to spend too much time on smoothing out everything. Maybe in the future. My main priority is to have everything mechanically correct and everything else refreshed. It's quite hard to paint a straight edge on these quite porous surfaces. You'd have to machine them or spend eternity to file them by hand. As much as I am a quite detail oriented and spent a considerable time on cleaning up and polishing, there is a place where you have to say enough is enough from the perspective of the place where you are standing. It's a resurrection, not custom correcting and customizing adventure.

I chrome plated some components of this assembly so they are well protected. Everything had been ultrasonically cleaned, soda blasted and pained black and clear coated. I used a bunch of very fine sand papers to wet smooth the cylinder bore. The last one was 2000. I used the old seal kit after cleaning, as it was in a good shape. It worked even when everything looked like caca, inside and out, when I purchased the bike (see the photos).

The dust seal installed was not the correct one, and I can't find any true reference photos. So I have a question - please see the last photo.







The top cover is just aluminum I've been trying to polish. It's not easy for the clean look.

I installed the Kawasaki original dust seal. But without any true reference photos, I am not sure if this seal should go over the 'lip' or the way I installed it. I admit I rushed in a bit, and I hope I don't have to take it apart. One thing, the hole on the seal seems very small in diameter and it fits and seals perfectly as is. It would have to be stretched quite far to go over the round 'disc'. The seal was quite expensive and I didn't want to risk breaking it. Could anyone fill me in on this?

Can't comment on the seal, but your work looks great!

Thank you Bucko! One by one!