Clutch master cylinder rebuild

[GlockPointer]

I got the allballs kit but the seals were way too big. I could see maybe a little difference after 24yrs between old and new parts but these weren't even close.
Problem is Kawasaki parts diagrams don't accurately show what is going on inside this master cylinder so I can't be sure of what to order.
I'm sure this one hasn't been tampered with or switched, but what is going on?
Now I have to leave the system down and maybe rebuild with 24yr old parts because it cant be down too long.
How did you rebuild if you did?

[ghostler]

When I rebuilt mine, I resorted to OEM parts. Yes, perhaps it cost a little more, but the fit was perfect, restored clutch action. I decided to go with a new piston, which worked out just fine. Helps to have the service manual. There is download link somewhere around here, just can't recall where.

[Avidrider62]

Piston (seal) is the main item. K&L makes a good kit.(32-1095) Most rebuilds don't need anything but a clean up inside. A 1/2 inch copper fitting brush works well. Clutch slave cyl was an issue awhile back for me.

[ghostler]

I went with a new piston because OEM PISTON-COMP-BRAKE, CLUTCH 43020-1055 ($46.39 Ron Ayers, was $32.18 when I bought 7/18/2014) was only available as an assembly, piston seal not separate. Rest of the parts I ordered put costs past that.

Got to concur with you there, Avidrider62. K&L Supply Master Cylinder Rebuild Kit - Clutch 32-1095, Amazon $32.76 & FREE Shipping on orders over $35 is certainly much cheaper than making up an order with OEM parts.

Appears to be a few differences between years on what master cylinders Kawasaki used, can't say specifically but that may be the reason why the kit GlockPointer purchased wasn't the right size. Or perhaps a previous owner replaced entire master cylinder with one off another bike?

[triton28]

The part number for the clutch master cylinder piston assembly, 432020-1055, did not change from 1986 through to and including 2003.
They did however introduce a diaphragm plate, # 43027-1055, for the reservoir cover in 1992 which would probably account for the master cylinder assembly having different parts numbers.
From 1986 until 1991 the clutch master cylinder assembly was part #43015-1307;
and from 1991 until 2003 the number was 43015-1507.
Dave

[ghostler]

The part number for the clutch master cylinder piston assembly, 432020-1055, did not change from 1986 through to and including 2003. They did however introduce a diaphragm plate, #43027-1055, for the reservoir cover in 1992 which would probably account for the master cylinder assembly having different parts numbers. From 1986 until 1991 the clutch master cylinder assembly was part #43015-1307; and from 1991 until 2003 the number was 43015-1507. Dave

Thanks for clarifying, Dave, I knew I saw it somewhere but didn't know the differences between. Also been having senior moments, not remembering when I ordered stuff until I looked at the receipts. So, if I have created some confusion by differing messages between edits, unintentional but hence why.

17 Sep, 08:09am Post edit: I purchased and installed the similar K&L Supply Brake Master Cylinder Rebuild Kit 32-1096 (Sold by: Powersport Parts through Amazon, $22.09 shipping included) during my front brake rebuild. Parts were perfect fits, which helps me that K&L parts are decent.