I had issues getting brake pressure. My rear caliper had the bleeder screw broken off, I pulled the caliper off, got it in a vice w/ easy out and snapped 2 off trying to back the screw out.

Not wanting to buy another caliper at the moment, I will in the future. I want to cap off the rear brake line at the brake distribution block under the front end. What size/type of plug would I need?

 

Just remove the rear line and match the fitting threads up at a good hardware store for a plug. Don't hold me to it but I think it's a 3/8" npt fitting.Dirt Cheap Yamaha, Honda, Arctic Cat & Polaris OEM Parts & Accessories – Cycle Parts Warehouse
http://www.ebay.com/itm/3-8-NPT-Pipe-Thread-Allen-Socket-Plug-Blue-PRE-63704-/330376456432?pt=Race_Car_Parts&hash=item4cebf8a8f0&vxp=mtr

 

Thanks opt, ill pick one up from advance on the way home and try it.

 

You might get one the next size up also..

 

so a 1/2 npt? 7/16?

 

7/16" also. Like I said don't hold me to the 3/8 npt..

 

I took the broken rear brake caliper to advance with me. He found a plug labeled 1/4 that fit inside the threads of the caliper. I took this home and tried it in the brake distribution block and it fit, was able to bleed front brakes fine.

I bled each side a few times, never saw much air or bubbles if any, yet i still have to pump the handle to get the atv to stop rolling. Is it still just air? This bike set up for 3 years until recently. How much is enough when bleeding these front two?

(Also put brand new pads on front 2)

 

When the brake lever is tight! If it's the least bit spongy there's still air in the lines. Plus if you have a hard time doing this on this 17 year old machine,could be the master cylinder seal leaking. Piston/seal kit is still available. http://www.cyclepartswarehouse.com/f...1997&fveh=5428

 

If I can hear a little air coming out of the piston when i let go of the handle does it need to be replaced? How hard is it, isn't there a retainer ring thats hard to get out? Not sure if I have the tools needed.

 

Probably the seal sucking air. This one just pulls out after you remove the lever if I remember correctly. Doesn't show a circlip on the breakdown holding it in. I used the installer kit,BUT if you're careful you can install the kit with out damaging the new seal.https://polaris.service-solutions.co...7&cat=1&sub=27