Okay so if anybody can help that would be awesome so i just got this fourwheeler for free from a buddy polaris 1998 sport 400 got a new tranny coming in this friday i need brakes so ill feel better on trails lol. The brake calipers are good both front and rear. BUT my front master cylinder lever is stuck like i went to rebuild it/clean it out and use it i cant get that piston to move at all ive tried everything from vise grips to monkey wrenches and big pipe wrenches lol wont move should i scrap the cylinder or is there anyway to fix it please help. PS ive tried to spray rust remover and cleaning stuff in it to try to help remove gunk and unstick it no luck i know it prolly ate the seals but hey 10 bucks for a rebuild kit that prolly was needed anyways to 120 bucks for new one whatever lol. PLEASE help

 

Remove the two screws holding the bowl and spray some penetrating lube in the spring piston area and see if helps.If the piston is that hard to get out,the cylinder may be corroded. You can get a high dollar replacement or a cheap Chinese that should work. Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse http://www.ebay.com/itm/94-99-POLARIS-SPORT-400-400L-NEW-FRONT-LEFT-BRAKE-MASTER-CYLINDER-CRUMPOL-/370810561680?pt=Motors_ATV_Parts_Accessories&hash=item5656082490&vxp=mtr

 

i have looked into the Chinese ones but they looked to small what size is the hole/thread for the brake lines to screw in or could you send me a link to one that would be amazing and i sprayed this stuff called rust remover ive used it before itll prolly eat the seals but i just want it out so i can rebuild it if it doesn't work you think i should just get that Chinese one?

 

http://www.ebay.com/itm/7-8-LEFT-SIDE-Hand-BRAKE-MASTER-CYLINDER-WITH-LEVER-for-50-70-90-110cc-ATV-Quad-/141453542831?pt=Motors_ATV_Parts_Accessories&hash=item20ef49c5af&vxp=mtr
Thats the one i was looking at but i didnt know if the hose would fit

 

May or may not fit, made for youth model machines. Have to remember you have two front brake lines along with the long rear line that branch off an aluminum block that work off the master cylinder.Capacity may be too small,plus take forever to bleed,plus may not have the stopping power. If you can't rebuild the original master cylinder at least get one that is designed for larger atvs.The one I linked to does.

 

I can speak from personal experience here. I have 2 Polaris quads ('90 trail boss 350L & recently a '97 Sportsman 400L both with bad brake lever/master cylinder assy's. I also have a few of the Chinese knockoff quads for the kiddos. The Chinese will NOT work because Polaris was nice enough to make the thread size completely different from virtually every other quad I've worked on.. I even looked into using an adapter to make the cheap one work, but more trouble than it's worth. I rebuilt my Polaris ones (1 successful, 1 failure). the failure was like what you have. By the time I got the piston out, the inside tube was just too corroded to keep pressure. Not to mention the "rebuild kits you see on eBay do not include all needed seals as they say. I just ordered them separately and came out cheaper than those eBay kits.

Anyhow, back to you. since you got for free and say the calipers and lines are GTG, I'd go for a new master cylinder handle assy. I bought 2-3 "used" off eBay and none of them were worth a crap (@$40-$75 each). I ended up getting a new one for about $120 (eBay) I think it was. Keep in mind I fooled with this one break system for 6-7 months off/on as money allowed. It was very frustrating especially since the 4-way is under the dang fuel tank.

Good luck with the build.

 

I can speak from personal experience here. I have 2 Polaris quads ('90 trail boss 350L & recently a '97 Sportsman 400L both with bad brake lever/master cylinder assy's. I also have a few of the Chinese knockoff quads for the kiddos. The Chinese will NOT work because Polaris was nice enough to make the thread size completely different from virtually every other quad I've worked on.. I even looked into using an adapter to make the cheap one work, but more trouble than it's worth. I rebuilt my Polaris ones (1 successful, 1 failure). the failure was like what you have. By the time I got the piston out, the inside tube was just too corroded to keep pressure. Not to mention the "rebuild kits you see on eBay do not include all needed seals as they say. I just ordered them separately and came out cheaper than those eBay kits.

Anyhow, back to you. since you got for free and say the calipers and lines are GTG, I'd go for a new master cylinder handle assy. I bought 2-3 "used" off eBay and none of them were worth a crap (@$40-$75 each). I ended up getting a new one for about $120 (eBay) I think it was. Keep in mind I fooled with this one break system for 6-7 months off/on as money allowed. It was very frustrating especially since the 4-way is under the dang fuel tank.

Good luck with the build.

 

Those master cylinders are designed so that you can knock the piston out by inserting a small punch into the hole where the brake line connects.

 

Thank you guys so much for helping. I actually think its a trailblazer 250 but im not sure because my friend has a 2003 honda 250 and mines bigger frame engine all that, ANYWAYssss off topic sorry. My brake lines and T valve are all corroded and bad anyways sooooo im just gonna have to buy new lines and a new master cylinder whats the best after market lines that will fit fine.

Goodridge Universal Brake Line Black W/ Black Ends - BikeBandit.com

I was looking into these but im not too sure if itll work says itll fit but we all know how that goes.

 

Just save yourself some grief and get the correct oem block for 20 bucks as it has the brake light sensor mounted to it and get any additional lines that are needed.Item#15-23.Dirt Cheap Yamaha & Polaris OEM Parts & Accessories – Cycle Parts Warehouse