So I rebuilt the caliper, rebuilt the master cylinder and replaced the brake line. I replaced the brake line because the old rubber one was looking kind of dry. The stainless one looks cool and matches the front lines.

I still can't get a hard pedal. Is there a chance I ripped one of the seals? Fluid is getting to the caliper, no doubt about it. When I assembled the caliper (and cylinder), I lubed everything up with fresh brake fluid and used a twisting motion to install the piston. Perhaps I jacked up the seal?? For the master cylinder I bought an aftermarket rebuild kit. I can't remember the company that made it, however the old and new pistons/seals looked identical.

What about the nipple that the reservoir line attaches to the master cylinder. That appears to be held on with one screw. I did not remove it but feel it might be suspect. Can anyone provide any info?

 

Dumb question, but did you bleed the brakes? If you didn't theres your problem.

 

Yes I have bled the brakes, over and over and over again.

Can anyone provide some useful info?

 

If I'm correct my 230 used the same caliper as yours. My brakes didn't work either so I took the caliper to the dealer and he said there was a thick washer (3/8)in thick that was missing. It held an o ring in place and without it itcouldn't hold pressure. Maybe yours is missing or it isn't seated correctly.

 

My buddy had the same issues with his brakes on his 200x. The problem was that one of the two extremely small holes on the shaft of the master cylinder was clogged. It took him forever to figure out that that was the problem. I've never done an lt500, so I don't know if it is the same as a 200x.

 

my lt250r has sorta the same problem, the rear brakes work, but slightly. like you said the pedal isnt hard, i cant get the brakes to sqeeze hard enough to completely stop me ever, so i rely more on the front brakes, which kinda sucks when in need off a jump to level out the quad.

 

On my 88' 500r, my brakes worked pretty good except for the fact it drags terrible, before I stripped it down, it was hard to push the quad!, anybody know whats wrong?

 

I don't know if the 500 has a parking brake/ or you've removed it, but if there is one it needs to be adjusted cuz its dragging.

 

I'm not familiar with the rear brake on a Quad Master but if it's similar to the King Quad, then it'll be mechanical with an adjustable cable from the foot peddle to the rear axleshaft brake lever. The manual calls this a "cam lever". And it describes the installation as such: When installing the brake cam lever on the camshaft, align the punch mark of the cam lever with the slit of the camshaft.
Do not over tighten the bolt. If you have this lever one tooth off center, it causes the brake to not engage fully or you won't be able to put the drum back on if too far in the opposite direction. If this doesn't make sense, talk to your local service department at the near by dealer. They should be able to talk you through it.
Chuck