Boxerworks.com

SteveD and GSPD,

Thanks.

Iv'e just re done the calipers and master cylinder on my 1978 R80, they were visually OK at first but with the tank off and squeezing the brake lever hard two things happened. first the master cylinder leaked fluid and as I was just about to release the lever ping, the clevis on the end of the cable flew off, the nipple on the end of the cable looked OK but on further investigation the hole in the clevis was far too big for the cable, so the entire system has been fully rebuilt/
So what was needed, master cylinder kit, caliper kit's including piston's as they were pitted and rusty in places, new brake hoses, and a new front brake cable and that was an issue as the clevis (2 off) were incorrectly sized, the hole for the cable was too big and the diameter for the one at the lever was too small, so I re used the old lever clevis and had to purchase the correct one for the master cylinder with the correct bore for a neat fit on the cable nipple.

What I found so far is that while this bike appeared to be all there and working someone did not know what they were doing when repairing or servicing this bike in the past, at least I have peace of mind in that the brakes are going to work and not surprise me.

I took my Brembo calipers apart and rebuilt them on my 1984 that I bought new. I changed the fluid regularly. as far as I could tell there was no reason to rebuild them. I tried to rebuild them with a aftermarket kit from Motobins that was touted as being better than OEM. KIt didn't fit so I got an OEM kit that was easy to fit and came with new caliper bolts.