Polaris Discussions about Polaris ATVs.

1998 sportsman 500 rear brake master cylinder replacement is different

Thread Tools
 
Search this Thread
 
Old Mar 3, 2018 | 08:23 AM
  #1  
unitoo1's Avatar
Thread Starter
|
Weekend Warrior
Joined: Feb 2018
Posts: 10
Likes: 0
Question 1998 sportsman 500 rear brake master cylinder replacement is different

Hey guys, I just ordered a rear brake master cylinder. everything seems to fit EXCEPT.,... the gold pushrod on my 1998 is hollow. so the foot lever screw and rest inside and does not slide around. It seems on the newer ones that golden pushrod is NOT hollow. So my threaded screw cannot rest inside of the master cylinder. The aftermarket for my year in non-existent it seems. Is there a way to put a new connection on the pushrod to connect to the brake lever? something that would HOLD the golden pushrod instead of my screw that nests inside the pushrod. Here is a picture representing how it kinda looks on mine. (this is not a picture of my exact one) I can take an exact picture of mine if needed. Look at the RED rod. That is coming from my foot brake lever going INTO the "gray" pushrod on the brake cylinder. Since the new Cylinder pushrod is SOLID my break level has nothing to hold on to. hope this makes sense? Is there some adaptor? Any ideas?
 
Attached Thumbnails 1998 sportsman 500  rear brake master cylinder replacement is different-static-schematic.gif  
Reply
Old Mar 3, 2018 | 09:03 AM
  #2  
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
Joined: Jun 2008
Posts: 24,350
Likes: 44
From: North Texas
Default

Seems like rebuilding your old master cylinder would be the way to go then as the seals were the main problem anyway.The seals would leak/suck air over time from non use.Before the seal kits came out you had to buy the high $ oem complete master cylinders. Then the aftermarket master cylinders came out.If it doen't work,just rebuild the old one.https://www.ebay.com/itm/1999-2008-P...!US!-1&vxp=mtr
 
Attached Thumbnails 1998 sportsman 500  rear brake master cylinder replacement is different-s-l1600.jpg   1998 sportsman 500  rear brake master cylinder replacement is different-e7977250e259940fde9d8c8cacd495464d899d6f.png  
Reply
Old Mar 4, 2018 | 07:33 AM
  #3  
unitoo1's Avatar
Thread Starter
|
Weekend Warrior
Joined: Feb 2018
Posts: 10
Likes: 0
Default

Originally Posted by old polaris tech
Seems like rebuilding your old master cylinder would be the way to go then as the seals were the main problem anyway.The seals would leak/suck air over time from non use.Before the seal kits came out you had to buy the high $ oem complete master cylinders. Then the aftermarket master cylinders came out.If it doen't work,just rebuild the old one.https://www.ebay.com/itm/1999-2008-Polaris-Sportsman-Trail-Boss-Rear-Master-Cylinder-Seal-Rebuild-Kit-126/270721609831?fits=Year%3A1998%7CModel%3ASportsman+ 500&hash=item3f0843f067:g:a6QAAOSwdzVXmO~i:sc:USPS FirstClass!75189!US!-1&vxp=mtr
Thx for the link! before I return this and get the seal, I was wondering if instead I could somehow replace the new golden pushrod with the old hollow goldern pushrod? Ive never taken a rear master cylender off, but I wonder if it is a swappable part? I guess it would have to be the same EXACT diameter. But hmmm it might be.... Has anyone ever swapped this part?
 
Reply
Old Mar 4, 2018 | 09:11 AM
  #4  
old polaris tech's Avatar
Polaris ATV Expert
Retired and loving it!
Joined: Jun 2008
Posts: 24,350
Likes: 44
From: North Texas
Default

Interesting,but no ones posted that I can recall of swapping piston plungers out because the hollow plunger style master cylinder was only used that one year.Possible it may swap over to the new body,but you may end up damaging the seals taking everything apart and swapping things over.
 
Reply
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
Rocko1012
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
7
Mar 4, 2015 02:51 PM
avf
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
2
Nov 5, 2013 12:26 PM
teamrev
Arctic Cat
19
Sep 18, 2010 07:54 PM
PolishCowboyPL
Yamaha
0
May 16, 2005 12:40 AM
AggieDaddy
Polaris
4
May 6, 2005 03:52 PM

Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 



All times are GMT -5. The time now is 10:45 PM.