Ok, after reading a bunch of posts on this exact problem (rear brake cylinder going bad on older Cats), I'm not sure what to do here. My wife's '04 400 4x4 auto has followed what seems to be the normal path to rear master failure. I took the machine to our local atv/dirt bike expert (where I have way more confidence that the local Cat dealer...) and he found the problem to be a bad master cylinder. He tried to order a rebuild kit but low and behold, Cat doesn't offer a rebuild kit. What's up with that? So now it's either buy a whole NEW m/c (for big bucks - like over $200), or try to cob something up. I'm headed off to Napa to see if they can match up these 'cups' that are actually the problem but can't be purchased individually from Cat.

I've read where some folks have replaced the entire rear brake system with parts from later year 500's with success. I'm up for that if that is a viable alternative to buying another '04 cylinder that will just go bad again.

Any tips or experience in this area that I can use to get us back on the trail? Bear???

[img]i/expressions/face-icon-small-confused.gif[/img]

 

I know the 04 and 05 650 V2's have this problem too and I read that some have replaced with a newer 700 rear master cylinder and haven't had any problems...

 

Hmmm. My question would be, does the change in frames and/or bodywork make any difference when it comes to fitting this stuff on? I'm looking for a 'no brainer' bolt up solution - [img]i/expressions/face-icon-small-wink.gif[/img]

 

After more searching I found that its just in the 04's and they are replacing them with the 05/06 style of master cylinder & remote reservoir.

 

So, this is for the "REAR" master cylinder eh? Do you know if it's a simple bolt on replacement, or do I have to do some 'cobbing' to make this fit?

 

After some more searchin. the 06 rear master cyl alone is too short to fit on the existing foot pedal. but the 05 kit comes with additional hardware to extend the brake shaft and mounting brackets for the new reservoir...

 

Ok, I got my bike back with the newly altered rear brake cylinder, ending the problems with not being able to get any repair parts from A/C. I posted the pictures in another string.

This setup works great and I'm looking forward to YEARS of trouble-free riding. [img]i/expressions/face-icon-small-cool.gif[/img]


See pix here:
http://forums.atvconnection.co...atid/5/threadid/548766