Help! CRG Ven99 Rear Caliper Rebuild

Jaime Cardenas · Joined: 12 Feb 2006 Posts: 24

Hi everyone,

I am getting my kart out of storage (5years) and when pressing the brake pedal, the rear calipers leaked brake fluid. My brakes are supposed to be Ven99. I noticed the leak came from the pistons that push the brake pads. Next I ordered a brake rebuild kit and tried taking the rear caliper apart. The strange thing is that after getting the pistons out, there doesn't seem to be anything else that comes out. But, the rebuild kit comes with o-rings and plastic parts. Inside the calipers, there appear to be some metal inserts? What should I do next? How do you the rear calipers apart and go about rebuilding them?

Thanks for any help.

Jaime

Walt Gifford · Posted: Tue Sep 18, 2012 4:27 pm Post subject:

After you take the pistons out there are rubber cups that come out next. A little puff of compressed air in the break line will pop them out. There are no O-rings on the pistons. see link.

http://www.cometkartsales.com/store/chassis/cpa/crg-ven99rear.htm

Gif Cool

_________________
FAA certified jet engine and aircraft technician
Nicholson Speedway class champion 2001
Yamaha KT100 Service Center
40 years karting experience

Rob Kozakowski · Posted: Wed Sep 19, 2012 12:00 pm Post subject:

Agreed with Walt.

Ven99 calipers are a pretty simple rebuild. They should have 2 pistons with the rubber "cups" behind them. Pistons should slide out unless corroded. The seals will come out with a shot of compressed air (preferred), or if they're being replaced by carefully (don't gouge any metal) extracting them with a screwdriver/etc.

It's not a bad idea to have a few extra fiber washers (item #5 in the picture in Walt's link) to make sure you don't have any leaks at the bleed screw.