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Okay...so I'm not seeing how the pushrod cover piece could possibly not hold the slave piston even in there.The piston is machined to allow the end to fit into the pushrod cover.There's a groove for it.See that?I think it's either(on yours) a matter of greasing the pushrod ends as per the manual or there's something going on with the master at the lever. Piston moving angled?I just can't see that happening.Not with the tolerances.
 

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Just put a little grease where the piston end touches the cylinder wall. The binding is a common problem, I posted a video here of somebody that has the trouble. Molly grease is already on the end of the rod from factory.
KHI and the dealers seem to try and avoid any direct answers yet the newer slave cylinders are of a modified type, there should be a recall.

The modified part number is 99999-0610.

I had this very issue last year in march...Kawasaki changed slave cylinder, push rod and input shaft. 3500 miles later in August that year bike lay for a few weeks and the problem happened again. Left it overnight went back out on it issue never came back rest of the season.

Went out today for the first time in 5 months....and 20 minutes on the bike the same thing is happening again. Pissed right off with this bike now.

Glad you managed to sort the issue yourself, I'm looking at doing the same this time as Kawasaki UK are useless. Can you explain in more detail where you put the grease and let me know if the issue has came back since you applied it ?

Cheers Ryan
 

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Discussion Starter #26
When you remove the slave cylinder have some grease ready because you need to hold the piston from slowly coming out. Where the piston meets the wall of the cylinder push some grease in the gap but not a lot as you want to get the grease to lubricate the sliding piston but not the seal. Molly grease because it penetrates the hone marks and stays there.



What's happening is the rod doesn't go deep enough into the piston causing it to tilt, you can feel the metal on metal sliding on the honing. The Hydraulics are very firm that it feels like the Mater Cylinder but it's not.


Didn't bother taking it to the dealer, just told them to log it as a Warranty fault.


Did mine a few moths ago, still fixed but eventually I will probably check the grease as part of an oil change.
 
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