I will bet you $20 I know the problem. I had a problem just like yours last year. You have to take a flash light and look under the cooling line that does through the break system and just below it you will see the brake switch. Its a peice that screws into the system with wires for the tail lights/brak light leading from it. Watch it closely and also listen. Start to pump the break lever and watch for tiny airbubbles/fluid comming from it. Watch the connection prongs where they come out of the switch and you should see the fluid come from there. Tell me what you find.
I got mine of a 96/97 XCR 600 I think..it came off an older sled. Check around if you know people with some poo parts from 98-96..maybe even the 99 uses the same part? Yeah I did what xcr440 said but I removed on side of the coolant line when I did mine. But yup just unbolt the caliper lift it up and take a wrench and unscrew it. If you have teflon tape it might not even be a bad idea to put a piece around it..but remember to put with the thred and not against.
Not sure if you know how to bleed it but you will see a nipple I belive just to the right of the calipar, looks almost golden color. First fill you brake fluid back up and put the cap back on. Unscrew the nipple about 1-2 turns and pump the brake handle, you will see fluid comming out. Keep pumping it untill you loose half or 3/4 of the fluid in the resovior then tighten it back up, refill the resovior. You will have to repeat this over a couple times, think I had to do it 3-4x so you can get the air out. Once you have done that fill it up again and pump and slowly tighten it again and pump it untill it gets hard. This make take some time but it should start to stiffen up. I think thats the procedure anyways to what I did. Hope it all works out.
haha..what a coincidence, i was just wroking on my brakes tonite as well..no leaks on my end, but i should take a peek at my switch just in case...My problem was that my brake light was staying stuck on, even though the brakes were disengaged...i ended up taking the caliper and pads off and cleaning and lubing the slides for the pads/caliper. I also cleaned and lubed the caliper piston as well. I then spent over an hour flushing and bleeding the brake system, i accidentally got a bit of air in the bugger so it took me forever, thought i would never get that damn air out...Finally got it worked out, started the sled and the light was staying stuck again...Cracked the bleeder to let a bit of fluid out and played with it some more and so for it hasn't come back on, so i am crossing my fingers it is fixed...didn't feel like driving around with the brake light stuck on and confusing the hell out of other riders...BTW its a Magura brake system...
I just bought my 97 XCR 440 SP, and it seems like a really nice machine so far, although i have not driven it yet. I agree to that there should be a separate forum for the 440 guys out there, they are a very unique engine compared to other sleds, and they seem that they need alot more tuning and all to get them to run how you want them too.
i wouldn't really say the engine is unique, maybe for its time, but it is based around the "liberty" family of engines in design..As for tuning I think they are easy to tune...Sounds like you do have a nice set up moto-ski man, you got pics? how was it tuning the UFO's? i know a few other xcr 440 guys on here are wondering..
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