TOPIC:

Hey Scotch. Nope, not that one. I've been reading the manual and can't find a reference to it, and actually there is not much about rebuilding the calipers - or I am missing something again... (that ring can be seen in a caliper cross section drawing though - figure J33 page 222 chassis maintenance, or page 230 in the pdf. file)
The first photo - before rebuilding. I am pulling the dust seal away from the thin metal ring which sits in the caliper body. You can see it between the body and the piston (the yellowish one).



Here, both calipers with pistons installed. The one on the right has all in place. You can see the rubber dust seal around the piston. The seal is attached to the lip of the 'L' shaped metal ring (visible on the left - before pressing it in) which is pushed into the caliper.
As the piston moves the dust seal expands. Now, when the piston moved further, that metal ring also came out of the caliper along with the dust seal. Perhaps the piston doesn't travel far enough after having it on the wheel, but when I was taking the caliper apart that ring was quite stuck in there. I am not sure if that's because of dirt and being old, or should I apply some adhesive (a thin layer of sealant?) to keep it there? I'd imagine not, because it's right next to the piston. On the other hand, the top part of the piston stays always outside (under the dust seal).
When I pressed that ring it stayed firm. But like I said, eventually moved when moving the piston in and out.



I am having a hell of a time installing the dust seals anyway.. First pushed the ring itself and couldn't fit the seal into the created groove (the ring of course doesn't go all the way inside so the inner lip of the seal goes into the groove). Unsuccessful - very tricky to pull that slippery rubber around the lip. Pretty tight and the lip has sharp edges. Then inserted the ring into the seal and pushed them both into the caliper with fingers (carefully not to cut the rubber). All looked good until I started pulling the piston beyond 1/2 and inch.

A very long paragraph about what seems to be otherwise a really frigging small detail that should be a simple no-brainer... Kind of a weird design by Kawasaki if anyone asks me...

There is a video of exactly like ours Kawasaki calipers servicing. That ring is there in place and the guy just puts the dust seal over it. So my question is - how to secure that ring inside the caliper beyond just pressing it in.

VIDEO

OK stan - Now I understand. That boot-ring doesn't normally come off so you can see why I was a bit confused. No one else jumping in on this so off the top of my head: High-temp epoxy? No real strain on this ring from the dust boot so it should work. Or wrap a piece of thin shim-stock (.002" - .004 ") 360 degrees and press the ring over that. A super-thin "Bushing", if you will. Don't know if the ring can be "shrunk" with high heat. Depending on the material used there's little control with this method.
Hope this gives some direction.

Thanks scotch. The ring goes in but doesn't stay as tight as should, I think no need to shrink it more? It might be that the red grease transferred to the ring and where it goes, and it makes it slippery. I might use red Loctite for it. A really bad design in my opinion.
Why not make a machined lip in the caliper itself?
Now I have to remove the pistons, clean up, and go shopping for epoxy or the Loctite.. I will also ask what type of 'goo' do they use for securing the header studs in the ceylinder head. Mine, at least, had some light brown substance hardened solid where the studs get screwed in the head.
No smooth ride with this bike...

My 2 cents worth (and I wouldn't pay anymore than that) when you cleaned up the caliper you may have cleaned of the paint in the bore the ring fits in. If it was me, I'd take a round bar and set it in a vise, then place the ring over the round bar and tap the outer diameter with a hammer to "stretch the ring to a larger diameter. It won't take much to gain a couple of thou and then reinstall everything.

The ring you refer to Stan, is, I believe the "seal stop" shown on page 126 of the manual. you would imagine it should be a tight press fit into the caliper. I wonder if the ring or caliper has corroded? Look here:

japan.webike.net/products/20878409.html

www.saisei-europe.com/Shop/Products/c/br...er-boot-stopper-ring



This one is listed for the Z1000.