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1998 XCR 440 Brake problem
- XCR 440
started by LANCER
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January 31st 2009 at 2:38 PM
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LANCER
Starting Member
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17 Posts
Group: Members
Member Since: January 19th 2009
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Here is my problem.I just replaced my brake switch because it leaked. Now the brake light on the dash stays on and as I drive it the brakes start to get hot and to the point the brake fluid expands so much the brake levercan't be moved. Is ir a caliper problem?
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Site Supporter
Group: Site Supporters
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January 31st 2009 at 3:28 PM
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Over an hour ago
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12582 Posts 
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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did you bleed the brakes??
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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January 31st 2009 at 4:04 PM
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LANCER
Starting Member
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17 Posts
Group: Members
Member Since: January 19th 2009
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Yes I blead the brakes. I am now taking apart the brake assembly by the caliper and the hand lever assembly and cleaning and inspecting for a possible vent hole blockage right under the resivor. If you have any suggestions I would like to hear them. Thanks
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January 31st 2009 at 4:10 PM
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Over an hour ago
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12582 Posts
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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try cleaning the bore and piston of the master, they have been know to stick.
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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January 31st 2009 at 4:45 PM
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CanadianXCR
New Ice Ripper!
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1642 Posts 
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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I had the exact same problem with my 98. The piston inside the master cyl was so gummed up it wouldn't return properly. All I did was disassemble it, give it a good clean, a little lube and reassemble. Fresh brake fluid and bleed the caliper. Its been 2 years now, no problems.
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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January 31st 2009 at 5:16 PM
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LANCER
Starting Member
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17 Posts
Group: Members
Member Since: January 19th 2009
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Well I have cleaned the piton in the break cyclinder and after starting and running it for about 5 minutes the break light came on and the breaks are getting to the point they are starting to seize up. Is there a different year sled I can take the break lever assembly of and use it? I am confused.
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January 31st 2009 at 5:29 PM
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wasnt this already discussed on xcr 440 owners?
****in sweet xcr 440
ported polished
bored out
2' paddle track
licence plate
hood
raditors
seat
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January 31st 2009 at 5:32 PM
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LANCER
Starting Member
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17 Posts
Group: Members
Member Since: January 19th 2009
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I am new to this site can you help me find this information?
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February 1st 2009 at 10:55 AM
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CanadianXCR
New Ice Ripper!
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1642 Posts
Group: Members
Member Since: December 18th 2004
Location: Barrie, ON, Canada
Current Sled: 1998 XCR 440
2008-2009 Miles: 0
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well you could use the search function or you'll notice a 90 page thread about XCR 440's...Lots of good info. You can swap out the master cyl and handle assembly for a Wilwood unit but you'll need fitting adapters.
98 XCR 440 / Woodys / Hot Seat Performance / Shock Pros / Cobra / Sportech / Fox / TEAM / Camoplast Ice Ripper
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February 1st 2009 at 12:10 PM
[ Modified February 1st 2009 at 12:15 PM
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tnmemr
Red
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506 Posts 
Group: Members
Member Since: November 7th 2006
Location: WI, USA
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Quote originally posted by LANCER
Well I have cleaned the piton in the break cyclinder and after starting and running it for about 5 minutes the break light came on and the breaks are getting to the point they are starting to seize up. Is there a different year sled I can take the break lever assembly of and use it? I am confused.
I installed a Wilwood master cylinder from an AC ZR. You need a fitting available from Wahl Brothers Racing to adapt the threads fromthe stock brake line to the Wilwood. I like the Wilwood. You can pick them up reasonably from ebay or others who are parting out sleds. You can also change to a master cylinder mounted brake light switch if/when your pressure switch fails. I'm condidering this now as my pressure switch failed and a new one from Polaris is $70.00 compared to $13.95 for the Wilwood form Wahl Bros.
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February 1st 2009 at 1:34 PM
[ Modified February 1st 2009 at 1:40 PM
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snowheadtrailbeater
hobby sled mechanic
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45 Posts
Group: Members
Member Since: January 30th 2009
Location: MI, USA
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try the slave end with hose disconected from master, if pistons push back in caliper easy its the master.
Hoses sometimes fall apart inside so check the inlet holes of brake line.
also brake light only indicates parking brake,cars have 4 slaves so they need brake light because brakes will work even if there is partial brake falure.
CHECK THE PARK BRAKE CABLE ITS PROBABLY FRAYED ON THE HANDLBARS>>>>>>>>>>>>>>>>>>
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February 1st 2009 at 4:45 PM
[ Modified February 1st 2009 at 4:45 PM
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Over an hour ago
|
12582 Posts
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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no parking brake or cable on the 440.
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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February 1st 2009 at 7:54 PM
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LANCER
Starting Member
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17 Posts
Group: Members
Member Since: January 19th 2009
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I figured it out. The break fluid expands and the pressure needs to be released thru the small hole in the brake resivor. After pulling the piston out of the hand brake assembly for the fifth time and watching it closly I found that the main oring on the piston was possitioned incorrectly.It was in front of the small hole causing no place for the pressure to go. So I ended up grinding alittle of the brake handle to allow the piston to pull back further so that the oring will be before the small hole. I have put 50 miles on the sled and all is well. Thanks for the input guys.
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