According to the shop manual (page 5C-7) Excessive Brake Pedal Travel is caused by:
Air in hydraulic circuit
Level of brake fluid in reservoir too low
Master cylinder push rod clearance excessive
Leakage in hydraulic system
I'm confused though. Why did the Tech open the hydraulic system anyway? I was under the impression that the rebuild kits only dealt with the electronic portion of the ABS. Replacing that does not require opening the hydraulic system.
The Tech should also not have had to do anything that would have damaged the Master Cylinder ... but it's also unlikely that the Master Cylinder would go bad at the same time as working on the ABS.
The likely scenario is that the Tech did not properly bleed the brakes. It's a fairly involved process on the VX. The instructions for bleeding the brakes is on page 5C-9 of the Shop Manual (I'll try to post that in a moment). The first thing you should ask the Tech is if he removed the 40A ABS fuse during the bleeding process. If he looks at you funny or says that's not standard operating procedure then tell the boss to have a different Tech repeat the bleeding process.
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