2000 Polaris sportsman hand brake lever - Polaris ATV Forum
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post #1 of 8 (permalink) Old 01-01-2016, 12:58 PM Thread Starter
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2000 Polaris sportsman hand brake lever

So I made a bonehead move and when I was tightening the lever bracket to the Handelbar, I went too tight and it broke... On the master brake lever side so I'm assuming I need to replace the entire master cylinder and lever? Or can I just replace the part that the resivore screws onto.

Any help would be appreciated!
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post #2 of 8 (permalink) Old 01-01-2016, 03:27 PM
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Did you break the clamp (#4) or the master cylinder? It should be cast aluminum and you could probably clean it up real well and rough it and use JB Weld to repair it. If it broke that easily it may have already been cracked.

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post #3 of 8 (permalink) Old 01-01-2016, 09:52 PM Thread Starter
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I wish it was the clamp. It's the Master cylinder and the part number is not listed in the diagram. Hmm jb weld.. Maybe I'll try that. What parts would I need to order if I go with replacing it?
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post #4 of 8 (permalink) Old 01-02-2016, 05:24 AM
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For replacement I'd get a good used one off ebay.
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post #5 of 8 (permalink) Old 01-02-2016, 07:56 AM Thread Starter
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Quote:
Originally Posted by polman500 View Post
For replacement I'd get a good used one off ebay.


I'll look. Would you know the part number off hand?
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post #6 of 8 (permalink) Old 01-02-2016, 01:43 PM
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Here's the machines that are a direct cross over although many others will work.


Year Product Model Assembly
2001 ATV SPORTSMAN 500 DUSE CONTROLS - MASTER CYLINDER/BRAKE LINE - A01CH50AD (4960026002B009)
2000 ATV MAGNUM 325 2X4 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CB32AA (4949354935B009)
2000 ATV MAGNUM 325 2X4 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CB32AA (4949354935B009)
2000 ATV 325 MAGNUM 2X4 HDS CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CB32AA (4949354935B009)
2000 ATV MAGNUM 325 4X4 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD32AA (4949404940B010)
2000 ATV MAGNUM 325 4X4 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD32AA (4949404940B010)
2000 ATV 325 MAGNUM 4X4 HDS CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD32AA (4949404940B010)
2000 ATV 325 MAGNUM 4X4 HDS II CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD32AA (4949404940B010)
2000 ATV MAGNUM 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD50AA (4954885488B009)
2000 ATV MAGNUM 500 EB CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD50AA (4954885488B009)
2000 ATV 500 MAGNUM 4X4, HDS CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD50AA (4954885488B009)
2000 ATV 500 MAGNUM 4X4, HDS II CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CD50AA (4954885488B009)
2000 ATV XPLORER 400 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CG38CA (4954875487B010)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AA (4957715771B010)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AA (4957715771B010)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AC (4959905990B011)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AC (4959905990B011)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AC (4959905990B011)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AC (4959905990B011)
2000 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH33AC (4959905990B011)
2000 ATV DIESEL CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH46CA (4954785478B009)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 RSE CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 RSE CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CH50AA (4954805480B012)
2000 ATV XPEDITION 325 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CK32AA (4954895489B009)
2000 ATV XPEDITION 325 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CK32AA (4954895489B009)
2000 ATV XPEDITION 425 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CK42AA (4949304930B009)
2000 ATV XPEDITION 425 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CK42AA (4949304930B009)
2000 ATV SPORTSMAN 6X6 CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CL50AA (4954815481B010)
2000 ATV INT'L BIG BOSS CONTROLS - MASTER CYLINDER/BRAKE LINE - A00CL50AA (4954815481B010)
1999 ATV XPRESS 300 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CA28CA (4949444944b006)
1999 ATV XPLORER 300 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CC28CA (4949484948b010)
1999 ATV MAGNUM 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CD50AA (4949254925B009)
1999 ATV XPLORER 400 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CG38CA (4949634963B009)
1999 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH33CB (4945964596b011)
1999 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH33CB (4945964596b011)
1999 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH33IA (4949884988b011)
1999 ATV SPORTSMAN 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH33IA (4949884988b011)
1999 ATV WORKER 335 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH33IA (4949884988b011)
1999 ATV DIESEL CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH45IA (4949154915B009)
1999 ATV INTL DIESEL CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH45IA (4949154915B009)
1999 ATV SPORTSMAN 500 RSE CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH50AC (4952455245b011)
1999 ATV SPORTSMAN 500 CONTROLS - MASTER CYLINDER/BRAKE LINE - A99CH50EB (4949114911b011)
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post #7 of 8 (permalink) Old 01-03-2016, 07:49 AM
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1998 Sportsman 500 - 4725 miles
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2010 Sportsman 500 HO - 1362 miles 182hrs
Front/Rear 18W-4 inch solid metal CREE LED Floods
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post #8 of 8 (permalink) Old 01-05-2016, 10:56 AM Thread Starter
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Thanks fellas, got my part on order. Any guides out there to replace this? I am assuming I will have to bleed the brake system when I'm done. At least I should not have to remove and of the lines
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