Hi All again,
Now I am working on the front brakes of what I was told is a 1987 Trail Boss 4x4. According to the previous owner he built this quad from a wrecked vehicle.

The problem is that the front brakes appear to be from a 1988 or newer trail boss however there is not enough clearance between the brake and the disk to install new pads. I am guessing that the previous owner knew this too so he just reused a worn out brake pad on the inside and a new brake pad on the outside.

Is there a problem with how the front hub was installed so there is not enough room for a brake pad? Can a spacer be added to the axle to move the hub out to accommodate a new brake pad?

Or do I need to purchase 1987 front calipers for this quad? The 1987 calipers are significantly different from the calipers used in 1988 and later.

Any suggestions are appreciated.

Pics attached. The last pic also shows the thickness of a new brake pad

The serial number on the frame looks like *1556801*

Thanks

 

You have to remove the 5/16" allen set screw from the caliper slide to have enough room to get the pads on. Once the pads are on,caliper mounted,brakes pumped up,insert the set screw and while slowly turning the rotor turn the screw in until you feel slight pressure on the rotor from the inner pad. Then back off 1/8 turn on the set screw. If that doesn't work you may have to try to find calipers for an 87 model which might be hard to find.

 

Hi OPT,
I did remove the allen set screw and there is still not enough room for the brake pad. In fact there is barely enough room for the base metal that the actual pad sits on. Hence the previous owner reusing a worn out pad for the inside. Ugh.

I might order some of the actual pads that fit a true 1987 caliper to measure the thickness and then decide if it is worthwhile to change out the calipers. If they can be found.

Thanks again!

 

Pads along with everything else are completely different on the 87 caliper.

 

Thanks OPT, it looks like the pads (10) actually fit inside the bracket (7) so that it would fit in the narrow gap on my quad. With the newer style caliper the bracket and the pad lay on top of each other so there is no way it will fit on a 1987 hub assembly.

Do you know of any way to confirm that the pads fit inside the bracket?
i.e. dimensions of the bracket and pad?

One seller on ebay mentioned access to a microfiche? I actually remember using microfiche many, many years ago.

Thanks again!

 

See if this helps.1987 POLARIS TRAIL BOSS 250 4X4 REBUILT RIGHT FRONT BRAKE CALIPER | eBay Several used calipers on ebay from 36 bucks and up. Most would need to have a new seal kit which shows in most places to still be available.

 

Hmmm, Really hard to tell if the pad fits inside the bracket. I also have to confirm that the bracket will bolt onto the hub. Probably should just buy one and see.

Would only be out $36.

Thanks again!

 

Yes! From this pic it looks like the caliper fits inside the bracket!

I will buy this one and test it out. Hopefully the bracket will fit.

Thanks a lot!!!