Hi, great site here guys. I am new and did a search and can't find the answer to my question. I'm a pretty smart guy when it comes to fixing stuff but for the lift of me I can't figure out how to get the pads out of my 1995 sportsman 400. Looks like 2 pins in there that shouls just slide out but they are stuck. I had the caliper upside down and full of PM blaster and they are still stuck. I got needle nose vise grips trying to move them and they just don't ant to come out. Any ideas?

My bleeded was broken off and I'm trying not to take the brake line off. I gotta be doing something wrong. They can't be this stuck. Not the best design I've ever seen. THANKS for any help....

 

If it's like my 92 trailboss, there is an allen screw on the caliper which when loosened lets the pads out. It's been awhile hope that's not miss leading.

 

My 94 Trailblazer had an allen screw also. I look and see if it has one. I think they where made for adjusting the pad side to side clearance.

 

I just pulled up the parts list or the 92 and it's close but not the same. The 95 sportsman has 2 pins that hold the pads. They are hels in by what looks like only the frame when you mount the caliper to the frame. The should just slide out I would think. I see nothing holding them in. I think they are just frozen in there. I just want to try to find out for sure. I may end up trying to carefully weld a small nut on each end to get a wrench on them to spin them out. I'll have to then grind it down. I am just hoping someone knows a trick or I am missing something before I start getting crazy. I may just end up biting the bullet and paying $170 for a new caliper. The pads have to be changed- they are down to he metal

 

definitly no allen screw anywhere.

 

Possibly behind a rubber boot? When loosened the pins are able to slide further in to let the pads clear for removal. Be patient.

 

I know there is not an allen screw. I even went to http://parts.polarisind.com/Assemblies.asp and checked out the exploded view of the 1995 sportsman 4x4 caliper. I really think they are just supposed to slide out when the caliper is removed. The back of the caliper sits on the frame of the machine and it would hold the pins in. I have it upside down and soaking in PB blaster for the night and I'll try again in the morning. If my bleeded didn't break off I'd just yank the caliper and it would make life easier. The brake lines also are 11 years old and they don't look like they will come off too easily either without breaking. It's an old but good quad. If you have time, check out the parts break down on it and you will see what I mean.

 

I looked at the same drawing I think they called it a set screw I'll check again.

 

model 958040? Item # 2 under front brake. set screw socket head.

 

Call me crazy but I still don't see it. I se where item #2 points to but it's the mounting hold for the caliper. I don't se a set screw anywhere? I'm going to run in the garage and quadtriple (no pun intended) check but I know I didn't se one???