95 4x4 sportsman 400 rear brakes - Page 2 - Polaris ATV Forum
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post #11 of 13 (permalink) Old 11-20-2010, 06:53 PM
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Location: Pine River, MN
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atvjunkie821 was right. Before I read his post, I tried heat... I tried multiple drill bits... nothing touched it. Then I went to the school where I teach and used a carbide endmill bit in our milling machine. It took a little time, but I got the pin out and the Magnum is back together and running tonight.

Thanks so much to everyone for the help!
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post #12 of 13 (permalink) Old 11-14-2013, 07:08 AM
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Location: Rockmart Ga
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rear brakes 1996 425 4x4

I have a 1996 425 magum 4x4 that has never had brakes replaced . I read about the pins not coming out so I sprated my pin with Kroil oil let set two days thay fill out . But now the piston want go all the way back likes about a 1/4 inch any body ran in to this .
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post #13 of 13 (permalink) Old 08-15-2015, 11:54 AM
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I'm rebuilding a 96 xplorer 300 and thought I'd tell everyone how I managed to get my pins out.

first I let them soak overnight with some penetrating oil and the next day that hadnt helped any so I broke out the dremel with a cutting bit and put a notch in the top of the pin. then I used a screwdriver to work the pin loose. that worked on one but the other was still stuck pretty bad so I hit it with an impact screwdriver and that broke it free. after working it around to get the oil in I was able to get it out with needle nose pliers.

my piston isnt going all the way back in also but I figure I need to just push it out and cleaned it up some. built up gunk from years of no pads on it.
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