I have a 1999 Sportsman 500. I got it used and from day one the brakes drag from time to time. I replaced the pads on the rear disc. I had Polaris replace the master brake cylinder for the rear brake. I rode it yesterday and the brakes drug soooo bad that the fluid got hot and I had no peddle or hand brake. My mileage sucks! I tried reverse and that worked for a short time and then it started again. I used WD-40 on the caliper and disc and it was so hot that it almost burned! After letting it cool off and then using both the foot rear brake and the hand brake in foreward and reverse it stopped. The next time I use it, it will start all over again. This happens every time. Does anyone know if either the caliper or disc should float?? Mine does not. Any help at all please!!!

 

The caliper should retract enough for the pads to pull away from the disc. Neither the caliper or disc should float, only the pads. Make sure the foot brake linkage is clean and working properly, with all pivot points lubed and moving freely.

If it is, I would replace the caliper, because I don't have the patience to waste time rebuilding it, only to have it leak. I'd rather tear it off, throw it as far away from me as possible, and install a new one. But that's me.

 

I had an idea that it may be the calipers that were not retracting enough, but I guess I didn't want to face that fact. So, I will take your advice and just replace the calipers with new ones. I feel like you - I don't want to take the time and work, just to have them leak and have to replace them anyway. In some respects I am a lot like the "other guy", just spray it with WD-40 and hope that it will go away. I am 65 years old and I use the Polaris SP 500 in my outfitting business. It is a great machine and I have used it over the last year or two to pack out deer, elk, and moose in Utah. It is a lifesaver and I don't do much backpacking the meat out anymore. You don't know haw much better I feel now. I am sure that is the problem. Thank You very much!!!
Happy Trails

 

You are welcome, good luck.