Rear Brake Caliper Fitting - Polaris ATV Forum
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post #1 of 7 (permalink) Old 05-20-2019, 10:23 AM Thread Starter
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Rear Brake Caliper Fitting

The rear brake caliper for my 04 Sportsman 600 showed up today. It came with banjo fittings instead of flared fittings. Is that the way they're supposed to be? Mine are flared fittings. I looked around on line and all I'm seeing are banjo fittings. I'd rather not have to buy adapters if I don't have to.

Thanks.

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post #2 of 7 (permalink) Old 05-20-2019, 11:54 AM
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Yeah, most of the newer machines use banjo fittings and its hard to find the reasonably priced ones that will work with the flared lines.
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post #3 of 7 (permalink) Old 05-20-2019, 12:34 PM
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The OEM caliper has inverted flare ports

Let us know where you find an adapter - I could find male pipe to inverted flare (would adapt your line to thread into a pipe threaded hole), male pipe to flare, inverted flare to female pipe (adapt the line you have to connect to a pipe nipple), a banjo to flare (adapt a banjo fitting to a standard flare fitting), a banjo bolt with a female pipe thread for a pressure brake light switch, but I could not find a banjo to female inverted flare.

You might just need a custom brake line.

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post #4 of 7 (permalink) Old 05-21-2019, 02:23 AM Thread Starter
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It turns out some of the relatively cheap calipers have both the banjo fitting as well as the flare. You have to read the fine print. Of course, mine didn't... I didn't bother going any further and just rebuilt my caliper. All is right with the world now... If I went the route of getting an adapter fitting, an -AN fitting probably would have worked fine. One of the seals in my caliper was missing a section about 1/2" long...

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post #5 of 7 (permalink) Old 05-21-2019, 04:51 AM
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Sounds good Hawk. You should be getting in pretty good shape now for work and play.
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post #6 of 7 (permalink) Old 05-21-2019, 04:54 AM
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On your tranny issue, did you ever try taking the linkage loose at the bell crank and see if you can put it in gear manually? If it'll go in that way you probably just need to adjust the linkage a little.
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post #7 of 7 (permalink) Old 05-21-2019, 04:57 AM Thread Starter
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Quote:
Originally Posted by polman500 View Post
On your tranny issue, did you ever try taking the linkage loose at the bell crank and see if you can put it in gear manually? If it'll go in that way you probably just need to adjust the linkage a little.
I haven't messed with that yet. I'm expecting that one to be more involved so I'm procrastinating a little... I'll probably mess with the linkage this weekend though just to see.

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