VX 800 Brake Caliper Rebuilds

Warning: Brake fluid is extremely nasty to painted surfaces.  Please be ultra-careful to not get any on your bike or other parts.  Keep clean rags and maybe some soapy water handy for quick cleanup.  While re-filling the fluid reservoirs, cover your tank, gauges, and other vulnerable parts.   As you work, it will be unavoidable to get brake fluid on the caliper's painted surface.  Remove the source by wiping out the inside as soon as possible, and then just be diligent in keeping your hands clean and wiping off any remaining fluid that comes out.
 

Got brakes that look like this?  Do they drag, or leak fluid?    Maybe you need to rebuild that caliper!

 

Brake system failures often occur linked to corrosion inside the calipers, or dirt and brake dust accumulating at the outer edge of the brake pistons.  This can be fixed by taking your calipers apart and cleaning or replacing any parts that need it.   I suppose if you are having problems with your brakes dragging, you could probably get away with just a good cleaning inside and out, and not actually replacing any parts.  But if your brakes are leaking from the piston area, then you will be in for a more thorough rebuild.

Your first line of defense it to change your brake fluid regularly.  DOT3 and 4 brake fluid will absorb moisture during it's lifetime.  That moisture will come into contact with the metal parts in your brakes and in time will cause all sorts of corrosion related problems.

I bought VX800 brake rebuild kits from http://www.ronayersmotorsports.com.  Their order line is 1.800.888.3084.  The price as of in November 2001 was $27.64 for the front kit and $53.15 for the rear kit, plus shipping.

front caliper rebuild kit - part#59100-01830
rear caliper rebuild kit - part#69100-45870

UPDATE: I re-ran the part numbers at RonAyers.com in November 2003 and found that the part number for the front has been superceded by 59100-01831.  Even better, the price is now reduced to only $19.92.  The rear part number still works, but it's price is now $38.51

There is a slim chance that I got the boxes mixed up before taking the picture.  So if you plan on ordering a kit for just one caliper, double-check the part# first!

According to the order guy, the sealing rings are available individually, priced at a very reasonable $2 to $3 each.  However he did say that the pistons and at least one of the dust seals were not available separately from the kit.

Here's some of the stuff you'll need to do the job:

  • New seals and/or pistons, o-ring, dust boots.
  • Clean DOT4 brake fluid from a closed container
  • LOTS of clean rags and paper towels.
  • Pans to hold the parts
  • Plastic baggies and zip ties or twist ties
  • Newspapers to protect the work surface
  • Socket wrenches and combination wrenches: 8mm, 10mm, 12mm, & 14mm
  • Allen wrenches: 8mm
  • Needle nose pliers
  • Vinyl hose to drain brake fluid.
  • A jar or pan to catch the drained brake fluid 
  • Compressed air (optional but highly recommended)
  • Dental pick or other suitable tool (ie tiny jeweler's screwdriver)
  • Cleaning and polishing tools (toothbrush, fine wire wheel, super-fine steel wool, high grit emory cloth, etc...)
  • High-temp silicone grease suitable for brake systems
  • New brake fitting crush washers (10mm or 3/8")
  • A new cotter pin for the rear brake torque bar
  • Torque wrench(s) with the appropriate ranges of measurement
  • A tool to  prime the hydraulic system might be helpful

These pages are meant to be read in order.  For example, some of the stuff needed for doing a front caliper is discussed in the rear caliper pages.  If you are planning on doing the front only, and skip ahead, you'll miss some important stuff.  After reading this whole series of pages, don't miss the links on the last page to some other brake rebuilding pages.

Enough with the parts and tools, on to the bike!  

 

Brake rebuild main page
 Rear caliper removal
Front caliper removal
Rear caliper disassembly and repair
Front caliper disassembly and repair
Installation and testing