I have two quads, one is 2000 400ex and the other is 2003 400ex. I also have a couple of dirt bikes.

On my dirt bikes, the front brake is very firm, become rock hard at about 1/2 travel, no way you would pull the lever to the bars.

On the 2003 the lever feels a little mushy, but stops firmly before the lever can be pulled to the handlebars.

On the 2000, however, I can easily pull the lever to the handlebars. The braking action is reasonable, but it just doesn't leave any room for error and it just doesn't feel right to me.

I have replaced the front brake pads, rebuilt the master cylinder and have bled the brake lines every way I can think of to make sure there is no air in the lines. I have even stood the quad on end and on its side to ensure that any air in the line would rise towards the bleeder.

Does anyone else have issues with their front brake?

Any ideas?

Rod

 

There might be air in the lines, you probally need to bleed the brakes. You shouldnt be able to pull the brake lever to the bars.

 

Don't use your front brakes...I don't....

No but really, mine aren't that tight when I go to use them....I can pull them back within a half an inch of the bar.

 

Front brakes should supply over 60% of your stopping power.
It certainly sounds like you still have some air in the lines.
I've never been real big on bleeders, I prefer the old fashion way of pumping the brake, hold it tight (second person comes in handy) then cracking the valves and tightening when the system looses pressure. Repeat for both side and pump alot of brake fluid through the lines and calipers.

 

You most likely still have air in the system, but check the condition of brake hoses also.

For brake bleeding, I really like using a hand vacuum pump, like mity-vac.

It gets all the air out the first time, every time.

Welcome to the forum.

 

I know its not what you want to hear, but it sounds as though you still have air in the lines. On my 99 400ex the breaks are very firm.

 

Like I have said, I have tried every way I know to make sure I don't have air in the lines, including the vacuum pump method. I have sucked an entire can of brake fluid through, pouring it in the master cylinder reservoir as it is sucked out the bleeder. And yes, I did both sides.

Rod

 

Didn't realize you tried a vacuum pump...

Check the rubber brake lines carefully, to see if they bulge anywhere when you are applying the brakes.

Also, if a rotor is badly warped, it can push the piston into the caliper, and then the master cylinder uses most of its travel to push it back out.

You mentioned it goes clear to the bar, is it mushy on the way there, or does it suddenly feel firm at the end of the stroke?

 

My 2000 400EX was the same way. I bleed them only to get the same response weak brakes. I fixed the problem when I put aftermarket Streamline brakelines on mine. My front brakes are now very firm and you can no longer pull the brake lever to the handle bars.

 

The rubber lines are getting old and starting to swell. Our 00 and 01 400ex's are starting to get this way. You can get new stainless lines off ebay for about $50.