Tengai front brake... - Kawasaki KLR 650 Forum
Other KLR's - 250, 600, Tengai, C Models, KLX... Discussion of all the OTHER KLR models.

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post #1 of 7 Old 03-17-2017, 09:18 PM Thread Starter
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Tengai front brake...

Any Tengai owners out there ever try to rebuild the front caliper? The Tengai has a dual piston front caliper, unlike the KLR650 which has a single piston. Here is a photo of mine which badly needed a rebuild which I was able to accomplish just by cleaning all of the existing parts and reinstalling. I would have liked to had a complete rebuild kit but could only find the parts for one half of the caliper as the second piston is of a smaller size and seals don't seem to be available. Anyone been able to source a rebuild kit for the complete caliper?
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post #2 of 7 Old 03-18-2017, 06:31 PM
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Did you try these guys? 1991 Kawasaki KL650 (KL650-B3) Front Caliper | CyclePartsNation Kawasaki Parts Nation
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post #3 of 7 Old 03-18-2017, 07:27 PM Thread Starter
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Jeff, I had found them at Bike Bandit but these guys are cheaper. A big help thank you!
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post #4 of 7 Old 11-25-2017, 07:16 PM
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Quote:
Originally Posted by 90Tengai View Post
Any Tengai owners out there ever try to rebuild the front caliper? The Tengai has a dual piston front caliper, unlike the KLR650 which has a single piston. Here is a photo of mine which badly needed a rebuild which I was able to accomplish just by cleaning all of the existing parts and reinstalling. I would have liked to had a complete rebuild kit but could only find the parts for one half of the caliper as the second piston is of a smaller size and seals don't seem to be available. Anyone been able to source a rebuild kit for the complete caliper?
I am trying to find info on how to dissemble the caliper so I can change the brake pads...how do I get the pads out?
I can't find anyone who has posted videos on this...
Any help would be appreciated, thanks.
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post #5 of 7 Old 11-25-2017, 09:03 PM Thread Starter
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Front Brakes

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Originally Posted by Slofiend View Post
I am trying to find info on how to dissemble the caliper so I can change the brake pads...how do I get the pads out?
I can't find anyone who has posted videos on this...
Any help would be appreciated, thanks.
Slofiend, I have a maintenance manual which makes everything much easier. Several are available on E-bay.
Per the manual:
1) Remove the disk cover.
2) Remove the caliper from the disc, and take out the piston side pad from the caliper holder.
3) Push the caliper holder toward the piston and then remove the pad from the caliper holder shafts (two).

I use a c-clamp to compress the pistons back into the housing making it easier.
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post #6 of 7 Old 11-25-2017, 09:46 PM
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Originally Posted by 90Tengai View Post
Slofiend, I have a maintenance manual which makes everything much easier. Several are available on E-bay.
Per the manual:
1) Remove the disk cover.
2) Remove the caliper from the disc, and take out the piston side pad from the caliper holder.
3) Push the caliper holder toward the piston and then remove the pad from the caliper holder shafts (two).

I use a c-clamp to compress the pistons back into the housing making it easier.
Hmm...interesting.
Okay thanks.
I found a maintenance manual on eBay I am just waiting on confirmation from the seller it is for the Tengai, if so I will pick it up as the Clymer manual is not specific for the Tenagi and the differences are killing me ha!
Thanks for the tip, I'll try that.
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post #7 of 7 Old 11-25-2017, 11:08 PM Thread Starter
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The maintenance manual I have is a factory manual and it says Tengai on the cover there were about a dozen listed when I got mine.
If you use a c-clamp to compress the pistons make sure they go in straight. If you get one cocked you will ruin the bore and may never get it out. I pressed on the pad to compress the pistons.
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