95 4x4 sportsman 400 rear brakes - Polaris ATV Forum
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post #1 of 13 (permalink) Old 03-29-2010, 10:36 AM Thread Starter
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95 4x4 sportsman 400 rear brakes

Just wondering how to remove the two pins on the rear brakes, the seem to only go in one way.
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post #2 of 13 (permalink) Old 03-29-2010, 11:12 AM
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Welcome to the board!

I tried setting my password to "penis" but it said my password wasn't long enough...
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post #3 of 13 (permalink) Old 03-29-2010, 11:17 AM Thread Starter
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thanks... so about the brakes lol
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post #4 of 13 (permalink) Old 03-29-2010, 06:42 PM
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I HAD TO DO THE SAME ON MY 96 500, IT WASNT EASY I HAD TO CUT THE PADS OUT THEN I COULD GET AHOLD OF PINS AND WIGGLE THEM FREE. when i reinstalled them i put neverseize on them hopefully if i ever have to do it again

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post #5 of 13 (permalink) Old 03-29-2010, 07:05 PM
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I use a small pair of needle nose vice-grips with lots of wd40. Start twisting them and they will eventualy work out.

It is better to remain silent and appear ignorant than to speak and remove all doubt
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post #6 of 13 (permalink) Old 05-12-2010, 12:03 PM Thread Starter
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FYI on the brake system of a 96 polaris 400 AWD if the rear brake pads and pins are not changed often, the rust build will deter almost every attempt to remove. IE I got one pin out, but the other pin, we tried welding a nut onto it to turn it out, with almost everything failing we finally sept enough, cut the pin in half wedged chisel in to make the gap wide enough to remove the brake pads, and then finally hammered down on the chisel, when that worked, we took a pin chisel and hammered down hard on the top to finnally have it emerge. only took about an hour and a half of painful work.

Note: Make sure you make the pins atleast a yearly check for rust or currotion, I would even go as far as removing the rear brake to see if the pins fall out, or need to be turned with pliars.
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post #7 of 13 (permalink) Old 11-18-2010, 06:05 PM
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I've got two nights work on trying to get the pins out of the rear caliper so I can change the brakes on a 1996 Magnum. I've tried needle-nose vise grips, JB-80 (twice as good), and heat from an oxy-acetelyne torch. Maybe I'll try cutting the pads out, but everything is so rusted.

Any other great ideas for this "wonderful design" from Polaris?

Steve
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post #8 of 13 (permalink) Old 11-18-2010, 06:27 PM
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I just changed mine a couple of weeks ago. I used PB blaster and a good set of needle nose visegrips. I clamped as tight as a could, and then hit the Visegrips with a hammer. After a few times the pin moved out some and then I could grip the pin from the outside. You could try this technique with some heat from your torch. This wasn't Polaris' most brilliant idea, it just plain sucks.

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post #9 of 13 (permalink) Old 11-19-2010, 08:21 PM
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Now I'm in trouble

I cut the pins with a cut off wheel. I got the brake pads out and one pin out, but the second pin snapped off almost flush with the body of the caliper.

So, now I have about 3/8 - 1/2" of pin stuck in the body of the caliper. I got out a drill, and tried drilling the center of the pin, but none of my bits would even touch it. (Very hard material).

What now? I'm thinking removing the piston, rubber seals, and heating the pin with a torch. Maybe that would soften it enough to drill it?????

What do you think?
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post #10 of 13 (permalink) Old 11-20-2010, 11:14 AM
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ouch, yeah those pins are very hard material, they are heat treated to be hard. Heating them up will not soften them any. The only thing now that I can think of is to mill them out with a carbide endmill. Do you know anyone with machining equipment or a machine shop? You might look on ebay for another caliper.

95 Magnum 425 4x4 , 518HO carb & air box, 12inch rear wheel conversion.

02 Magnum 500 RMK

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