![\"\"](\"http:\/\/exhaustnotes.us\/blog\/wp-content\/uploads\/2020\/08\/1-600-2.jpg\")
<\/p>\nThe KLR250 refurbishment has been going slowly but in addition to that I\u2019m not getting much done otherwise. It\u2019s the heat. Temperatures at Tinfiny Ranch have been hovering around 100 degrees or more and under these conditions it\u2019s all I can do to press paper firebricks.<\/p>\n
<\/p>\n
I did manage to order a brake caliper kit from England. The Widow Maker\u2019s front brake gave me lots of problems at Daytona this year. The caliper was mightily stuck and the master cylinder was odd feeling. I managed to get the brake working well enough for Bike Week and replaced the master cylinder in a previous R, R & R episode but I didn\u2019t trust my half-assed Florida Man repairs on the caliper.<\/p>\n
![\"\"](\"http:\/\/exhaustnotes.us\/blog\/wp-content\/uploads\/2020\/08\/2-600-2.jpg\")
<\/p>\n
The Brakemasters rebuild kit was very complete and was inexpensive to boot. The Widowmaker\u2019s original rubber parts lasted through 20 years of neglect so the new stuff has a steep hill to climb. The only part I didn\u2019t care for was the new bleeder nipple. The replacement nipple did not want to thread in easily. I could have forced it and remolded the aluminum caliper threads but instead used the old nipple, which threaded in by hand.<\/p>\n
As expected, the caliper job went well. Old motorcycles with single-piston calipers are a breeze to repair. The hardest part was fitting the dust seal into the caliper body and then fitting the piston. I didn\u2019t remember how I did the trick last March and was getting frustrated. Thank goodness for YouTube; I pulled up a quick search on caliper dust boot installation and there was a guy showing me how to do the deal.<\/p>\n
![\"\"](\"http:\/\/exhaustnotes.us\/blog\/wp-content\/uploads\/2020\/08\/3-600-2.jpg\")
<\/p>\n
I think in March I used a beer can to make an expander sleeve for the piston and then slid the piston into the (already installed in the caliper) boot. It just wasn\u2019t working this time. Maybe fresh rubber is stronger than 20-year-old rubber. YouTube man fitted the boot to the piston first (the opposite of what I was doing) and let a short length of rubber hang off the back. That hanging bit was then pushed and prodded into its groove on the caliper. Once the dust boot is in the groove the piston can be slid into the caliper all the way until the piston groove catches the other end of the boot. With all the talk of grooves this sounds confusing but that\u2019s why YouTube videos are so nice. YouTube Man\u2019s method worked great and the caliper is now ready for reinstallation.<\/p>\n
If it cools off a little I\u2019ll tackle the fork seals and re-grease the steering head bearings next. And keep making firebricks, of course.<\/p>\n
More on the KLR250 and other moto-resurrection stuff is on the ExNotes Resurrections<\/a> page!<\/p>\n","protected":false},"excerpt":{"rendered":" The KLR250 refurbishment has been going slowly but in addition to that I\u2019m not getting much done otherwise. It\u2019s the heat. Temperatures at Tinfiny Ranch have been hovering around 100 degrees or more and under these conditions it\u2019s all I can do to press paper firebricks. I did manage to order a brake caliper kit … Continue reading “Squeeze Me: KLR250 Refresh, Reflash and Rehash Part 3”<\/span><\/a><\/p>\n","protected":false},"author":2,"featured_media":9734,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"jetpack_post_was_ever_published":false,"_jetpack_newsletter_access":"","_jetpack_dont_email_post_to_subs":true,"_jetpack_newsletter_tier_id":0,"_jetpack_memberships_contains_paywalled_content":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[64,66,140],"tags":[12,1349,214,1348,1347,1195,1072,1057],"class_list":["post-9732","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-gear","category-joe-gresh","category-vintage-motorcycle","tag-joe-gresh","tag-joe-gresh-resurrection","tag-kawasaki","tag-kawasaki-brake-overhaul","tag-kawasaki-klr","tag-klr-250","tag-motorcycle-maintenance","tag-motorcycle-restoration"],"jetpack_featured_media_url":"https:\/\/exhaustnotes.us\/blog\/wp-content\/uploads\/2020\/08\/0.jpg","jetpack_sharing_enabled":true,"post_mailing_queue_ids":[],"_links":{"self":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/9732","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/users\/2"}],"replies":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/comments?post=9732"}],"version-history":[{"count":5,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/9732\/revisions"}],"predecessor-version":[{"id":9741,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/posts\/9732\/revisions\/9741"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/media\/9734"}],"wp:attachment":[{"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/media?parent=9732"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/categories?post=9732"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/exhaustnotes.us\/blog\/index.php\/wp-json\/wp\/v2\/tags?post=9732"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}