So... I was replacing the rear wheel bearings on my 02 sportsman 500 and while i was putting everything back together i used a screwdriver to stop the brake disk from spinning while i tightened the wheels. Long story short, I forgot to remove the screw driver and when I drove the quad it snapped the rear caliper. I know I will need a new caliper however I'm not sure what it was connected too, crank case?

My questions:

1. How can I bypass/plug the back brakes temp so I can use the quad for plowing my driveway, while I order the replacement parts.
2. Can anyone tell from the pictures what the caliper gets screwed onto?

Thanks in advance for any help or suggestions.

Scott

 

Doesn't matter about line 6 as it goes from the small rear master cylinder and separate from the main brake lines. Line 5 is the line you need to block off as it ties in to the "tee" block with the two front brake lines. Try a good hardware store about finding a cap to block off this line leading into the caliper. Then bleed the front calipers to remove any air. Used calipers are on ebay. Ooops, took a second look at the caliper mounting pic and see that you've broken the caliper mounting studs on the transmission. No way to mount a caliper.. have to live with front brakes only by blocking off line 5 or finding a used transmission.. Sorry that this happened to you..

 

Thanks OPT for the quick reply AGAIN! You have been awesome with the all my questions/problems. Dumb mistake by me on this one!

Is there anything you would recommend capping the line with?

Scott

 

Again a good hardware or auto store can usually help. Remove the lines and take the caliper in to find the right size fitting. Finding a cap then will be easy. Think it's a 7/16 x24 pitch fitting but don't hold me to it...

 

I know these are a little old, but this forum has saved me countless times. I signed up just to thank you guys for the help! I busted the inner portion of the brake ramp assembly on my '97 Sportsman. I can't find anything that'll work. Any advice, Mr. Polaris guru? Again, thanks for the countless hours you've already saved me.