My brother has an 04 Trail Boss and the rear brake pedal goes all the way down. The brake works well otherwise. He also needs to replace his rt. foot well that broke when he was hit by another rider. This damage didn't affect the brake pedal and the handle bar lever works fine too.

I mention the foot well because the missing plastic (broke off) allows him to press the pedal down far. When he replaces the foot well he won't be able to push the pedal down as far as he can now.

So I told him how to bleed the brake hoping this would reduce the pedal travel - no luck.

He does see some (very little) moisture at the piston of the rear master cylinder. The fluid was and is full. Partsland wants $109 for a new master. Does he need a new master? What do you guys think? Oh yeah, do you think Partsland is the cheapest place for the foot well?

Thank you

 

Did you check the hoses for leaks? Make sure the piston in the master cylinder is getting the full stroke forward and backwards. Many people check to see if it is going all the way forward but never check the other way. If it cannot come all the way back it will not pickup any more fluid.

Also you need to check the fluid every year and chage it every other year. Don't just check to see if there is some in there but the condition of the fluid. I have ran into these problem not only on my quad but on my Harley. The best way to bleed the brakes is pressure; air or pedal. But some times on my Harley is to gravity bleed which is to take the top off of the master cylinder and then open the bleeder screw then go inside an eat a sandwich. This allows enough time for the air to work its way out.

DO NOT MIX DIFFERENT TYPES OF FLUID
THIS IS DANGEROUS!!!!

I hope that this has helped. Maybe someone has a better way but this has worked for me.

(Going fast is only cool if you can stop fast)

 

springerpete,

Thank you for the reply. He only has the moisture (no Leaks) noted. The fluid condition is clear and clean.

Let's just say the system is well bled, and the piston does not travel the full stroke, how can this be fixed?

In the mean time, I will send him your thoughts on bleeding, fluid condition and piston travel.

 

Does that "air pressure" trick work on your quad? What do you have? I've got to bleed my Sportsman foot brake system, as it's squashed out...must have air in it...I had the dealer do it last time, since it was in there for another item.

 

I think that I said it the wrong way. The air pressure is a hand pump that pushes the fluid from the bottom and forces the air bubbles from the bottom to the top. The pump belongs to my friend who used to be a Honda mechanic so I don't know where he got it.

I have a 2000 Scrambler 400 2x4. We bled it by gravity and then finished it with the pedal. I bought it used over a year ago. The fluid was very cloudy and full of moisture so we rebuilt the brakes and then completely flushed the system. It now has more pedal and more handle than ever before.

 

I talked to my brother and he doesn't think the cylinder is moving to it's outer most position. He needs to make it right.

Now does he need to do a better bleed, or is their a way to fix the cylinder travel to give him LESS pedal travel?

 

I would think that once you fixed the cylinder movement that the amount of pedal would be limited by the fluid movement and pressure, provided all the air is removed.