Hello,

Sorry for only answering now, I´ve only had tine this weekend to check the back calliper and its working OK in both sides, i think the problem was that the brake pad´s have less than a millimetre wide, so I´ve already ordered a new ones.
Has to the foot master cylinder i don´t see any leaks from it but it gets no pressure when pressed, can this be solved by rebuilding it?

Thank you all for the help

 

Common problem on the rear master cylinder seals to dry up and suck air from not being used that much.Get the rebuild kit for the small rear master cylinder. Plus a Mityvac is still the best and fastest way to bleed the system.

 

Hello old polaris tech,

Once again thanks for your help.
Where can I buy this kit for the best price in the Internet?

Another thing i need is the service manual for this model, do you now where i can download it for free?

I don't have the Mityvac, but what i do is similar, but in reverse mode, i use a big syringe and inject the brake fluid from the calliper to the fluid reservoir in the hand brake until i see no bubbles coming from the holes.

 

Same kit I showed earlier on ebay.http://www.ebay.com/itm/POLARIS-TRAIL-BOSS-REAR-BRAKE-MASTER-CYLINDER-SEAL-REPAIR-KIT-DR16-/271954333239?hash=item3f51bdce37&vxp=mtr&rmvSB=true Will fit all models of the Trail Boss. Plus no free manuals anymore that I can find,but 5 bucks isn't bad for one. Again this is a 2002 manual and the 325 Trail Boss didn't change that much during the 2000-2002 model period they were produced. Here's the link.2002 Polaris Trail Boss 325 Service Manual PDF Download

 

Thanks

I´ve already ordered both of them

 

Hello Old Polaris Tech,

I´ve just changed the rear brake master cylinder seal kit but now i have a new problem that i can´t solve.
When pressing the cylinder piston, it goes inside, but is very slow getting back, it seems stuck. I have already disassembled it and remount but still have the same problem.
What can be cause this?

Thanks again for the help.

 

Take some 4x steel wool (0000) and polish the piston shaft to make sure there are no burrs and that it's smooth. The seal lips need to be wet and pliable for the piston to operate properly. They make a special seal grease we used when rebuilding shocks/front forks but you shouldn't have to have it.

 

Thanks,

I will polish the piston shaft this weekend, i don´t have the grease you talk, but i have one that i normally use in the front fork of my bike, i thing it will be enough.

 

Hello,

The problem was not the piston, but the assembly of one of the rubbers that i changed, now it´s moving ok. But i still have the same problem that the pedal does not brake at all, i´ve already bleed the brakes several times, but still does not work.

What can i do more?

 

Then what's left is the rear caliper seals. There are two small seals that seal each caliper half along with the seals for the pistons. If either of these small seals are leaking/sucking air, the rear brake won't build up pressure. Here's the rebuild kit # that's used on your machine.Polaris Magnum Trail Boss Xplorer Rear Brake Caliper Seal O Ring Kit 2201385 | eBay