I have a '02 Scrambler 400 2x4, I have had nothing but problems with the rear brakes. I am always having to vac. bleed them before every ride and now the bleeders are frozen shut. I want to change the rear caliper and possibly the rear master cylinder. Before I start researching and fabricating I was wondering if anyone has done this to their machine, any help from someone who has done this would be appreciated.

 

I have an 04' scrammy and have given up on the foot brake. Everytime I bleed it it works for 2-3 times then stops again. All 3 of the guys I ride with that have polaris quads have no foot brake. It must have been a bad design and just never fixed it. My self I never used it that much anyway as the hand brake does front and rear so it is better except when going down a steep hill [img]i/expressions/face-icon-small-shocked.gif[/img] then you have to pump it so you can still steer.

 

Same here. The foot brake for the rear brake hasn't worked on all the bike. I gave up a long time ago. There are some parts out there that can convert the hand to the fronts and the foot pedal to the rear.

 

I know about the splitters for the brake systems, RCR sells them. Seems to be a common thing with Polaris rear brakes not working, nearly everyone I know with a Polaris has rear brake issues. I think I will just have to research and engineer my own rear brake system, something that actually works. I've been looking at Wilwood calipers, and some of the Harley calipers and rear master cylinders look promising too. I'll just have to make my own pads for them but thats cake. I use to be a certified diesel mechanic and now I'm a welder with access to stainless and mild steel, my brother is a machinist, so this is a project well within my capabilities. I just wonder why Polaris never bothered to correct this problem? They could save money by not even installing the rear brake system!

 

I did away with my front brakes,ran my single back brake line to a block then out to the rear with 2 lines.It will lock up the rear without any problems.

 

i custom split my brake setup.the rear brake will lock right up,even on black top the tires lock up as good as my buddies 400ex..the fronts work but not as well as i want them to,they are still the stock pads though..i hate when the parking brake doesnt hold pressure and the machine rolls into my truck[img]i/expressions/face-icon-small-mad.gif[/img] anyone know a fix for the parking brake issue?

 

yeah mine suck also. polaris calls them auxillary so I think the gentleman a few posts up was right when he suggested that it may be a bad design

 

I wonder if the problem with the rear brake master cylinder bleeding back too much fluid when the bike is traveling down hill
I know that the brakes get all screwed up on old cars that have the master located physically lower than the brakes themselves.
this is usually cured by using a residual pressure valve to prevent too much fluid from returning to the master

do an ebay search for residual pressure check valve

might be something to try

 

I have the same problem with my wifes 2002 also, but I have a ??" for CED. Are you still useing the stock rear claipers. And do you have a pic of your set up maybe.
I figure if your still useing the stock rear, then Ill work on the pugger change out.\

Thanks guys.

 

and here I thought I was the only one with this problem. I usually have to pump mine and set the parking brake and they tend to hold until I get home but if I park the truck at work I have to repump and set them before going to lunch/home or to ride after work. it really ticks me off.