When I replace the brakes on a 2001 400 4x4 do I remove the whole caliper or do I just remove the 4 hex bolts which will allow the calipers to separate. Thanks in advance for the information.

 

Direct from the service manual. 1. support the ATV on a sutable stand. 2.remove the right rear wheel and account for the cap screws. 3.Loosen the rear cable adjuster jam nuts; then remove the cap screws securing the mechanical brake to the axel housing. 4. Remove the brake pads from the caliper. INSTALLING.. 1.Place the brake pads into the caliper. 2slide brake caliper assembly over the brake disc and into position then secure the caliper with the cap screws (coated with blue Loctite #243) tightened to 2.8 kg-m(20 ft-lbs). 3 Install the wheel and secure (50 ft-lbs). 4. Adjust the brake. NOTE: new pads must be burnished. Hope this helps good luck..

 

I just finished doing this very same thing on my 400 and 500. Remove the caliper but don't take it apart. If you take it apart you will have to bleed the system. Use a flat object like a wood file or something to press the caliper pistons back in the bore. Make sure they go in evenly. Definetly burnish the pads when you are done. Good luck. I did both of my quads (6 sets of pads) in about 2 hours.

Dakota R/T

 

Thanks for the advise it was very helpful....I replaced front and rear brakes, all pistons were froze in the calipers...450 miles who would have thought?

 

I replaced the seals on mine last weekend when I did the brake pads. The sand and mud I ride in does nasty stuff to my cats. Keep riding and good luck.

Dakota R/T

 

Hey Dakota, where did you get seals?? I was told by more than one shop that you couldn't get parts for the calipers. They also told me that a caliper is a $115. I was not happy to say the least.

 

Try calling Arctic Cat and see if they will send you new parts. The brake calipers should last a lot longer than that! Sounds more like an assembly/manufacture flaw. Good Luck!

 

115!!!!!!!!! Dang, The brake calipers on a 1991 Dodge Cummins dually are only 25 each.

The 2000 and older models have a different brake caliper than the 2001 and newer models. This might be why he could get parts for them.

 

Well in my manual it shows how to disassemble the calipers and it shows 2 sets of seals. What it does not show is a number indicating the pistons of the calipers. hmmmmmmmm

 

I took out the piston because it was leaking just a bit around the edge. The seal came right out after that. My dealer too said it was not servicable. I went to a motorcycle shop and the guy had boxes of caliper seals. No brands or anything just simple seals. I bought 2 different sizes and took them home and the first one fit. I only needed one replaced the rest where just fine.They where just generic seals. Try a good motorcycle shop because the aftermarket bads from EBC where made to fit motorcycle calipers so it must cross reference somewhere. I hope that helps but there was no part number or anything else I can give you to help. best of luck.

Dakota R/T