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I just got done modifying a 2000 500 sportsman and noticed the brake lever was not returning to its full seated position. All 1999, 2000 magnums, xpeditions, xplorers, and sportsmans also the 2001 duse had a composite brake lever. These machines had the nut over torqued from the factory causing the brakes to always be applied. Most people will never notice, but if you run your machine hard and the fluid gets hot it will apply the brakes causing them to wear out in a couple of hundred miles. Easy fix just loosen the nut and re tighten it lightly, squeeze the brake lever and make sure it returns to a full seated position.
 

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Thanks for the update DIRTY!:wiggle:
 
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