Lost brakes 98 Scrambler!

[3 Polaris Atvs]

I take my Scrambler out of storage yesterday for preparation for next weeks trip. I start it several times a winder so that is no problem. I have owned this since 2000. My son rides it around the back of the house and I pressure wash it with my new toy. I wash this quad at least once a year this way. I now tell him to ride to the shop for maintenance. He get it in the shop and NO brakes. I pump the lever and hear a leak and I see fluid by the rear master cylinder reservoir. I pull the side covers and fill both reservoirs and first pump the foot lever, no pedal but I never use it any way. I pump the hand lever and fluid comes out the rear reservoir seal? Is there a check valve some where that is bad and causing this. I cant believe washing it made any difference. Need to get this fixed soon. Leaving for Wisconsin for 3 days of riding Thursday.

[BADASSDAD]

98 Scrambler 500 Replaced front and rear master cylinders. Bled and bled and bled this thing! Apply the top brake and fuid forces past the lower master cylinder and overflows the reservoir.Apply the foot brake and fluid runs out of the top master cylinder.Ay my wits end and extremely FRUSTRATED at this point!Somebody out there has to have encountered this before? As I have had no problem at all finding others with the same problem.Still looking for the guy with the freakin amswer!!! I just know im gonna feel dumb when I find out!

[polman500]

I haven't seen that particular problem before but the rear pedal MS does go bad on those machines often and it is not rebuildable and expensive to buy new. It would be my guess that you've got seal(s) blown in the rear caliper letting the fluid bypass. You could try to find a rebuild kit on ebay but would probably have more luck just finding a used rear caliper.
For a quick fix, you could take the rear brake line loose from the splitter block that divides the fluid coming from the handle bar MS to each front wheel and to one side of the rear caliper and plug that outlet in the block off. Then you'd have only front brakes while you try to locate parts to fix the rears. I think the block on those machines is located under the front plastic on the frame or you may be able to access it from underneath in front of the engine near the steering shaft.

Good Luck!

[polman500]

After reading my post, instead of "MS" I meant "MC" (master cylinder)...sorry for any confusion.

[BADASSDAD]

Thanks Polman.I think you nailed it!Talked to a polaris tech at the local dealership this morning, He echoed what you just said.It is in the rear caliper. That the piston in that caliper is stepped.Rear m/c pushes on one part. Front on another! Probably a bad o ring or diaphram.Removing and checking tonight.Will keep you posted!

[polman500]

Glad to be of assistance.

[BADASSDAD]

Indeed Flat o-ring in piston! Disassembled and found one cut thus letting fluid pass from one side to the other! $3.00 part MASSIVE HEADACHE!!

[3 Polaris Atvs]

Originally Posted by BADASSDAD

Indeed Flat o-ring in piston! Disassembled and found one cut thus letting fluid pass from one side to the other! $3.00 part MASSIVE HEADACHE!!

Where did you find replacement parts? Part numbers?

[BADASSDAD]

Did find on Ebay. $15.00 out of Florida! Going to check local dealer tomorrow.Also going to check a local industrial supply company. I'll keep you posted!

[3 Polaris Atvs]

Pads wear out and it cuts the seal. I was pressed for time and went to the local dealership to get this kit. 48 dollars and change out the door. Less than an hour from off the quad to overhauled to back on an bleed. Simple repair.