200x braking system questions

[oscarmayer]

I was needing to redo the brake system on my wife's 200x i'm doing. the front master resivore is trashed and the master cyclinder does leak a tiny bit. Here's my thoughts.

front- get the front off a newer ATV and use that as it will have a metal resivore attached. front fixed then. (thoughts? known models that work?)

rear- rear is hydraulics operated off of a foot pedel only. my idea since I'm going with an auto shifter (200e motor) for her was to install a newer ATV rear master on the left side of the bars. I know that can run to the rear no problems (long enough line), but what about the foot pedel? I want to use that still as well. ideas on how to do this?

[AutoXer]

thought quite a bit about this and the pedal and lever gets complex but I do like the lever idea I know 4x4 utility quads run a lever on the left then run a ss line to the rear

[The Goat]

I think something off of a 185s can be rigged up for a pedal if memory serves right.

Best master cylinders I see out there are off of the yfz...all alluminum no plastic.

Don't forget, one of those calipers I sent you is off a dirtbike, and you can get ANOTHER one for the front I think.

[Dirtcrasher]

All depends on you fabrication skills.....

I'd ditch the <200X pedal and peg and find a way to run and mount a 350X and or 86/87 peg with brake pedal and mount incorporated.

If thats not possible, I'd adapt a pivot point onto the stock <85 200X either onto the frame or the peg backing plate.

Then it's just a matter of relocating or building a linkage for the stock master or changing it to one that would be easier to fab up to.

Hell, I'd be more than glad to build a "kit" for you guys with auto X conversions.

I'll make 10, sell 2 and break even on the materials and nothing for my time. Soooooooooooo, why bother :lol:

Just use my thoughts and make your own :D

[AutoXer]

the 185s pedal works very well but idk how to use it and a lever

[RapidRick]

Does this help

http://www.files.3wheelerworld.com/MagScans/autox.pdf

[oscarmayer]

^ very interesting.

but that still does not resovle my issue about wanting a lever and a pedel for the rear break setup. What rear master can let me do both? (cable and hydraulic is still better than nothing.)


DC how much for a complete bolt on kit to get a rear pedel setup as well as soemting that I caus eu as a front lever for the rear brake? (hopefully that makes sense.)

[Dirtcrasher]

Why couldn't you just put a "T" in the line and run the front brake master to the rear brake line??

It can't push fluid into the rear master, should work fine......

[Erics350x]

polaris used a set up that had a lever and pedal, i think would work pretty good

[oscarmayer]

dirt, are you sure it won't caue an issue witht he lever master? I thought about that and was afraid the master was not strongenough to handle the reverse pressure. a T would be simpliest for sure!

Eric, polaris has a setup like that? hrmm I may have to investigate!!! I'm also going to check on one of them chinese quad makers as they seem to have a lot of weird parts that woudl probebly suit my needs.

Thanks for the info guys, Your definatly giving me good ideas!

DC do you knwo if the master can take the backpressure that woudl be presented by the otehr master? if so, that's be easiest to "T" into as I'm going with new custom stainless lines anyhow.

[inv3ctiv3]

I've got a nice set of front and rear brakes for sale off a '83 200x ;)

[Dirtcrasher]

All I'm providing is ideas :D

If there is a backflow issue, you would need a check valve, basically a ball and spring.

Check the Polaris fiche and see whats in there/how they do it.......

[racerxxx]

I've been looking into a 300ex of 400ex front master cylinder set up for my 200X front end conversion. It looks I dentical to and early R master cylinder, you just have to make sure the hose comes off the front of the resi not the side, the best thing is they're abundant on Ebay for around 45 bux, I guess everyone upgrades the stockers. I have not tried it yet but will eventually buy one to try.

http://cgi.ebay.com/ebaymotors/2005-TRX-300EX-FRONT-MASTER-CYLINDER-300-EX-400EX_W0QQcmdZViewItemQQ_trksidZp3286Q2ec0Q2em14QQ hashZitem518ce2e0faQQitemZ350256029946QQptZMotorsQ 5fATVQ5fPartsQ5fAccessories

[oscarmayer]

yea I'll have to do some design work. once i get it, I'll post it up and you guys can pick it over for feedback.

[Dirtcrasher]

Honestly, the more I think of it:

I "back bleed" my brakes often. I hook a hose onto the bleeder and force it up THRU the hose and into the master. I just can't remember if I have to pull in the brake lever for it to bypass or if it does it on it's own??

I forget, but with a bit of research I'm SURE it can be done with parts out there for sale. I love to make my own crap but a one way valve would suk to make.

Make sure you check the Polaris crap, I'm curious how they do it.......

[racerxxx]

Hey Oscarmayer,

I saw some where that KTM bikes use a hydraulic clutch set up, not sure if it coud be adapted to work for brakes or not but worth looking into. Found these on Ebay. This has got me thinking, but if you "T" the line you will definitely need flow control on both sides of the T. Just not sure of the bleed back to release the pressure. We've used these on rods where the master cylinder is lower than the rear wheel cylinders or calipers, but they keep slight pressure on the wheel cylinder side so that all the fluid does not bleed back, just not sure if 2 lbs is too much pressure on the rear caliper and would cause the brakes to drag too much. Just brainstorming out loud.

http://cgi.ebay.com/ebaymotors/HON-KTM-KAWA-Hydraulic-Clutch-Master-Cylinder-Cup-Lever_W0QQitemZ370184261884QQcmdZViewItemQQptZMoto rcycles_Parts_Accessories?hash=item5630b390fc&_trksid=p4506.c0.m245

http://cgi.ebay.com/ebaymotors/HYDRAULIC-CLUTCH-LEVER-MASTER-CYLINDER-PIT-DIRT-MX-LV07_W0QQitemZ160296621439QQcmdZViewItemQQptZMotor cycles_Parts_Accessories?hash=item25526c557f&_trksid=p4506.c0.m245

http://cgi.ebay.com/ebaymotors/Hand-controls-hydraulic-clutch-brake-master-cylinder_W0QQitemZ170387256441QQcmdZViewItemQQptZM otorcycles_Parts_Accessories?hash=item27abdf3479&_trksid=p4506.c0.m245

Brake pressure check valves:

http://cgi.ebay.com/ebaymotors/2-Pound-Residual-Brake-Pressure-Check-Valve-Street-Rod_W0QQitemZ280400789156QQcmdZViewItem

[Autophysn]

Does this help

http://www.files.3wheelerworld.com/MagScans/autox.pdf

things like that is what makes this site worth its weight in gold! Excellent find my friend, thank you for sharing

[oscarmayer]

sweet data guys!
wow! $449? holy cow!!!! lol little more than I was lookin for that 1 setup, but I do really like the other stuff. Gives me some ideas.

http://cgi.ebay.com/ebaymotors/POLARIS-SPORTSMAN-500-REAR-BRAKE-CALIPER_W0QQcmdZViewItemQQ_trksidZp3286Q2ec0Q2em14 QQhashZitem3a53520f73QQitemZ250505990003QQptZMotor sQ5fATVQ5fPartsQ5fAccessories

What do you think of that caliper? woudl it be possible to get it to mount to my 200x? it's got 2 hydro inputs! so that's rear and front hydro levers!!! ;)

[oscarmayer]

ok just got a brain storm.
the 200x has a e-brake cable setup to work off the clutch lever correct? where does that lever connect and cna I use that as the brake connection point for the front lever?

[oscarmayer]

ok peopel said ATV, anyone have a clue what yr and model i can use or try?

[night4creeper]

a 94 polaris sportsman 400 4x4 has the dual lever/pedal setup. i had one in for a repair a while back. might be a place to start.

[hondahaulic]

make a custom caliper bracket in the rear that will hold 2 small calipers!:lol: it would be a little ghetto, but should work. 1 caliper for the pedal and 1 for the hand lever. both on the same disc

[mmiguy2103]

all polaris models od 4x4 have a duel setup like your liiking for i would check them out and custom fab one on your trike

[oscarmayer]

cool. thanks guys!