Tip for getting the cylinder out if its stuck, you can put a punch down the other side, with the spring and hammer it out, mine was really stuck and even after the seal was removed, couldn't pull it out. Seals on mine were not bad, just a ton of black gunk in there that was causing it to get jammed and not return fluid into the bore sticking the brakes on. Thanks for the video, helped a lot!
Thanks for the tip! I think maybe that's what's happening to mine? I can bleed them, then go for a test drive and they begin to lock up, I guess I'll have to take apart and try to figure out, I have a aftermarket one on the way but maybe it just needs cleaned 🤷
@@whatsit2ya247 Same thing happened even after I rebuilt the master. I ended up snaking the rubber brake lines with a bicycle shifter cable to clean it out, that seemed to clear it up. But I'm fairly certain it needs new flexible lines, they'll pass fluid out but won't return it, so the calipers lock up.
@@Kingsoupturbo Mine wouldn't return either, the fix ended up taking the upper master cylinder apart and I noticed after taking the fluid reservoir off that one of the holes that goes to the cylinder was completely clogged shut, there's a big one and a tiny one,( it was the tiny one) poked it with a small pointy poker then reamed it with a small torch tip cleaner, cleaned everything up, put her back together and that did the trick 😁
@@whatsit2ya247 Very nice! old fluid can sure get gunky, and little chunks for the rubber lines deteriorating. I tried to find a lower cost solution for new flex lines, but they have an odd size fitting. next time I do the job I'm going to put another master cylinder to the rear brake, the combination block that splits all three is so very hard to bleed.
What would cause a 99 sportsman 500 to have brakes that are only effective when both the foot lever and hand lever are pressed? The hand brake lever also causes overflowing from the rear overflow resivour (under the seat), it feels like a one way valve somewhere has gone bad. Ideas?
Hey bud good video I have a 2001 Polaris 400 sportsman but sportsman obviously I have the left hand break then I have a reservoir underneath the seat seat that takes more of brake fluid how do I bleed that system system and it has on the caliper caliper I have 2 bleed screws Appreciate your comment
@@TheTechGuider You have to hook the line up quickly. If you dont squeeze the handle it won't suck air. But yes air will still be in the line so you have to bleed the brakes.
Hey T man thanks for the videos been watching a few years. I have 94 and 96 sportsmans. 94 hasn't ran in 5 years 96 is a nice unicorn. Brakes went out on 96 so replaced all pads and put on dry China master. Instead of trying to find the kit you said to get at parts store to bleed master I took the tank off. Thinking I can take the Master hose out of the block and use the jar method. Tried think the wrench was bending some, now have it soaking in break free. I noticed you changed to a braided stainless hose with a banjo so wondering if you tried what I'm doing and broke off? Any advice?
Yeah, the line nut going into the block didn't budge. Its soaking in break free now. I thought about putting heat to the block but there are a lot of wires there.
hey man im having trouble with my cam. the decompression lever seems really loose. the manual says not to preload the spring one full turn but the recommended preload of 1/4in seems really weak. barely holds is self. is this normal?
@@TheTechGuider I guess depends on how weak the spring is. Probably best to leave it where it is supposed to be. I had a really weak spring when I did mine.
Tip for getting the cylinder out if its stuck, you can put a punch down the other side, with the spring and hammer it out, mine was really stuck and even after the seal was removed, couldn't pull it out. Seals on mine were not bad, just a ton of black gunk in there that was causing it to get jammed and not return fluid into the bore sticking the brakes on. Thanks for the video, helped a lot!
Thanks for the tip! I think maybe that's what's happening to mine? I can bleed them, then go for a test drive and they begin to lock up, I guess I'll have to take apart and try to figure out, I have a aftermarket one on the way but maybe it just needs cleaned 🤷
@@whatsit2ya247 Same thing happened even after I rebuilt the master. I ended up snaking the rubber brake lines with a bicycle shifter cable to clean it out, that seemed to clear it up. But I'm fairly certain it needs new flexible lines, they'll pass fluid out but won't return it, so the calipers lock up.
@@Kingsoupturbo Mine wouldn't return either, the fix ended up taking the upper master cylinder apart and I noticed after taking the fluid reservoir off that one of the holes that goes to the cylinder was completely clogged shut, there's a big one and a tiny one,( it was the tiny one) poked it with a small pointy poker then reamed it with a small torch tip cleaner, cleaned everything up, put her back together and that did the trick 😁
@@whatsit2ya247 Very nice! old fluid can sure get gunky, and little chunks for the rubber lines deteriorating. I tried to find a lower cost solution for new flex lines, but they have an odd size fitting. next time I do the job I'm going to put another master cylinder to the rear brake, the combination block that splits all three is so very hard to bleed.
Great videos. Very informative. Tip. Hose clamp the second seal like a ring compressor.
Awesome late night upload
Excellent video took mine apart cleaned all the parts had to stretch the spring and put it back together whole lot of bleeding but I have brakes now
That's a good idea. I'll have to try that on my next one I'll be doing soon
Thanks for helping us keep these old dinosaurs going
You bet! It kills me when I see them parted out.
What would cause a 99 sportsman 500 to have brakes that are only effective when both the foot lever and hand lever are pressed? The hand brake lever also causes overflowing from the rear overflow resivour (under the seat), it feels like a one way valve somewhere has gone bad. Ideas?
What size are the screws that hold it on the handlebars
Hey bud good video I have a 2001 Polaris 400 sportsman but sportsman obviously I have the left hand break then I have a reservoir underneath the seat seat that takes more of brake fluid how do I bleed that system system and it has on the caliper caliper I have 2 bleed screws Appreciate your comment
th-cam.com/video/8zUAy3hAcUw/w-d-xo.html Check this one out.
Great video. Where do you get rebuid kit i have 98 sportsman 500
Spring is broke
Check out ebay
How dose the baffle sit inside 1997 polaris xlt 600 limited master brake cylinder
Snowmobile
how did you take the bleedr fitting off the master and put the brake line back on without sucking in air
You bleed the master after you install it. then bleed the lines. I was able to keep the fitting upwards and top it off with a syringe.
@@TitaniummanGarage yeah but after you take the bleed kit off the master doesn't
it suck in air?
@@TheTechGuider You have to hook the line up quickly. If you dont squeeze the handle it won't suck air. But yes air will still be in the line so you have to bleed the brakes.
Hey T man thanks for the videos been watching a few years. I have 94 and 96 sportsmans. 94 hasn't ran in 5 years 96 is a nice unicorn. Brakes went out on 96 so replaced all pads and put on dry China master. Instead of trying to find the kit you said to get at parts store to bleed master I took the tank off. Thinking I can take the Master hose out of the block and use the jar method. Tried think the wrench was bending some, now have it soaking in break free. I noticed you changed to a braided stainless hose with a banjo so wondering if you tried what I'm doing and broke off? Any advice?
I replaced the line because it was so corroded inside. Are asking if it broke in the junction block?
Beware of the china master. I had issues with those. I couldn't get the master to bleed. That's why I rebuild them now.
Yeah, the line nut going into the block didn't budge. Its soaking in break free now. I thought about putting heat to the block but there are a lot of wires there.
hey man im having trouble with my cam. the decompression lever seems really loose. the manual says not to preload the spring one full turn but the recommended preload of 1/4in seems really weak. barely holds is self. is this normal?
I've done it both ways as long as it has some play and not preloaded where it won't turn.
@@TitaniummanGarage so as long as it turns easily it should be good?
@@TheTechGuider Yes
@@TitaniummanGarage which way would you recommend
@@TheTechGuider I guess depends on how weak the spring is. Probably best to leave it where it is supposed to be. I had a really weak spring when I did mine.