Had anyone else had problems with the rear brakes failing or coming apart on the sportsman 800

 

on the rear caliper there are 2nuts with rubber caps on them. take the rubber cap off of the one break line that is for the foot pedal. you should see a small nut with a little hole on top of it. take a small piece of clear hose say 4" long that has a diameter that fits right over this little hole. You want the hose to be tight around this little hole, but not so tight that you cant get your wrench around the nut right below it.
Fill this hose with about 2" inches of break fluid and bend the end of the pipe so it is bending towards the ground.
Now go to your foot pedal and remove the cap of the brake master cylinder, use a small funnel if needed or just pour it in as you go. The key here is to NOT let any air into here.
Losen the bolt on the caliper with the hose on it very slowly and as your doing that tap the brake pedal with your hand. Do not completely press the pedal down or you will push out to much fluid. Just tap it over and over and you will start to see bubbles in the clear hose. Keep tapping until the bubbles stop but you will also need to keep adding fluid up front to keep the air from coming in.
The reason I say bend the clear hose down is by doing so, gravity almost does the work for you. It may take quite of few taps on the pedal, but once the bubbles stop, tighten the bolt on the caliper, add desired fluid, put the cap on and you should be good to go.
Its almost a 2 man process but you should only have to do it once. I did it on my scrambler and havent had a problem since. It may take you a couple times, but you will figure it out. good luck

 

good instructions on how to bleed brakes but i am looking for problems directly relating to brakes failing due to mechanical issues. thx

 

What was your specific problem. Details please. I have a 700 and the bikes are the same except for the CCs and the Primary clutch. THX

 

Lost BOTH of my pads on my 03 sp700. Ruined caliper also. Just was out trailriding and somewhere it came up missing.

 

Upnort, just the kind of thing i'm looking for thxs for the reply !!
Madmatt, my 05 800 rear brake caliper broke allowing the pad to come off while riding causing a temporary COMPLETE brake failure.

 

I'd file a compalint with the NTSB to make sure the failure is properly reported. Take pictures of the failed part befor ethe dealer replaces it. Also make sure you make copies of any warranty repair slips the dealer gives you for the NTSB and document if they give you a hard time.