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Discussion Starter #1
I couldn't bleed my rear brakes, even with a new Master Cylinder and everything on it. I bought the Master Cyclinder, etc. from the guys at Precision-Aircraft, makers of the Ridgerunner Buggies....they gave me a tip to bleeding the rear brake....

This is only the foot brake I am talking about, as there is usually no problems with the balanced front/rear handlebar brake.

I had the top filler cap off of the resevoir and then I put a heavy weight on the brake pedal itself and left it on there over night....this forces the cups open/out within the master cylinder....it appears the problem is on many machine (probably not all) is that the cups retract within the master cylinder enough that they won't give a good seal and you get leak-by on the cups and not enough pressure to operate the caliper....

So, after leaving it over night, I went out there this morning, took the weight off, worked the brake pedal with my right hand and the bleed nipple with the other hand, the brakes bled right out, they work better than they did coming from the factory....

now, we'll just have to see how long they last, but at least I know how to get them bled again...
 

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my goofy Polaris dealer told me, when not using quad for any length of time to leave a weight on brake pedal and air in line "shouldn't" be a problem.
 

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my 800 sits for a few days, up to 7 sometimes without being moved. should I be putting a weight on the brake pedal, how much is a lot of weight for this.
How do u check to see if the caliper is sticking like u say, dave ??
 

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Discussion Starter #4
Allen,
If you run in to problems with your brakes, i.e. you notice that the foot pedal is going down further and you are loosing brakes, then you probably want to put a weight on it...

The size/weight of the weight is something that will sit on the pedal and hold it all the way down...

if it gets to this point, you may have to bleed the brakes, almost all Polaris machines run in to the problem sooner or later...
 

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interesting posts, the rear brake on my mag 500 is great ,the 04.5 sptsmn is almost non existent, thanks,dave, for the good info...
 

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when i hit the foot lever, not much seems to happen, they work, but not nearly as well as it seems the pedal should. Maybe that is how it is supposed to be since it is designed to be operated from the hand lever. I dont know. maybe I should just bleed them to be sure.
 

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The foot brake should hold you in place on a grade, but don't expect it to do much in terms of slowing you down... the rear brake is only a single disc on one wheel compared to discs on both front wheels.

It took two replacements of the master cyl under warranty before my footbrake worked worth a darn. It seems mine had that seal problem that Dave spoke of.

Rob
 

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Discussion Starter #8
another note from above....leave your cover on the resevoir when you let it sit overnight, since brake fluid is prone to moisture and affecting the way it works, will screw up the boiling point, so leave the cover on when letting sit overnight...
 

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ok. i doubt mine would hold me on a hill if I just pushed on it.
That suck ! I am starting to get ticked off with this polaris. I have had an axle, break, maybe my fault. The gas gauge is screwed up and now, obviously, I have the same brake issue as everyone else. Starting to think I should have got a honda.
 

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Allen, I had a Rincon before I got the Sportsman and I ended up HATING IT. Couldn't wait to be rid of it. The Sportsman is the BEST ATV I've ever owned, and I used to think that of my Grizzly, despite it's fuel boiling issues.

Hondas are not bulletproof. My Rincon was SLOW. Top speed on GPS was 48 MPH and it stalled constantly. None of the three dealers within a two county area back in Nevada were interested in working on it even under warranty... I got the runaround all the time.

On top of that, the lack of a low range gear and locking differential made it every difficult to ride in technical areas, which is where I preferred to ride.

After that experience, especially with the dealers, AND a call to Honda itself to complain, and being told they weren't going to help me, I'll NEVER own another Honda product again.

Rob
 

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Discussion Starter #11
I agree with Rob, I have owned every major brank and like the Polaris the best, especially the new sportsmans.

As far as the axle, go read the other forums at other sites, they break them all the time...I broke one, but considering what I did, it would have broke on any machine, I popped the CV, like you did, weakest point...

and the gas gauge, if you mean it not dropping off full right away, I haven't seen one that records the fuel right, on any machine...but I know what it does and how many miles I have, I don't rely on the gauge....

I've got my Error code 51 back after hunting this past weekend, now I have to figure that out again, it was the loose bolt going through the coil last time, I think it is the plug wire or something this time, I didn't replace it last time...
 

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I guess maybe it doenst matter what u own, all u have is problems out of this hobby. My gas guage is annoying though. I thought of getting one of the mechanical ones to replace the stock gas tank cap.
I hope you get your problem figured out. If your going to have problems, its at least nice when u for sure know what the problem is.
 

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The mechanical ones suck too!
I have the cap style on my Scrammy.

Jim
 

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so im confused are u leaving the cap on tight or lose.. is the weight on the brake forcing air out the top of the cap while it in place ? it says dont leave cover off over night but how is it forcing air out otherwise?
 
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