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2003 Sportsman 700 Brake Performance

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Old 03-24-2018, 09:16 PM
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Default 2003 Sportsman 700 Brake Performance

ATV had sat for two years when I got it. Brake system had drained empty. I replaced the main master cylinder and put new seals in rear caliper. Ran a bunch of new fluid through both front calipers and installed EBC sintered pads all the way around. The old pads were not metal to metal yet so the rotors seem okay. The brakes work, including the foot brake on the rear, but I think they are a little weak. Should I be able to lock the front wheels? I've tried this on wet grass and they will not lock. Lever and pedal never lose pressure, and I can set the parking brake for days on end and it's still holding tight. Do I need to rough up the rotors? Is this normal?
 
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Old 03-25-2018, 08:21 AM
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If you replaced the master cylinder,seals on the rear caliper,I'd replace the seals in the front calipers.They have the most stopping power. If they don't have the seals could be seeping a little. https://www.ebay.com/itm/Polaris-par...paSEZa&vxp=mtr
https://www.ebay.com/itm/Polaris-541...1Z5NCm&vxp=mtr You need two of the 779,two of the 780 seals. Shouldn't have to mess with these drilled and slotted rotors other than an occasional wire brush.
 
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Old 03-25-2018, 08:29 AM
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Should I be able to lock the front wheels? I’m just trying to gauge the expected performance.
 
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Old 03-25-2018, 08:53 AM
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The split system gives most of the braking to the front,60/40 by most counts. If the brakes are in good shape,yes you should be able to lock the front wheels under heavy braking.
 
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Old 03-25-2018, 09:02 AM
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I’ll rebuild the front calipers and wire wheel the rotors and see what happens. Thank you!
 
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Old 03-25-2018, 02:23 PM
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Went ahead and wire wheeled the rotors today. Totally different machine now! The brakes work great. I think I’ll still replace the front caliper seals but it seems the rotor finish was the ticket. My next project is the ball joints. They are the worst I’ve ever seen.
 
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