[09z71]

I'll cut to the chase. 1991 trx300 4x4. I can NOT get the front brakes to work. I've replaced the master cylinder, which I bench bled first. I've cleaned all the pistons in the brakes. I've done a one man brake bleeder. I've done the vise grip method. I've done it the old school pump 3 times then hold.

There supposedly isn't any air in the system. I'm getting fresh fluid out the bleeders.

Does anyone have any other suggestions??

Also why won't the disc brake conversion work on a 91?

 

[Goober]

You have air in the top of the line. Take out that little puck in the bottom of the MC and you’ll see air bubbles rising. Jiggle the brake handle and move the bars slowly back and for to let the air in the cable rise.

 

[09z71]

I don't have that in mine

 

[fishfiles]

I done a Super ATV disc conversion on my 92 1st gen , even though they don't list your 91 as compatible , go for it , it will work -----pinch the rubber brake hose right out side the master and pump it a couple of times , if the lever gets hard and holds the pressure then the master is good ---- could be brake adjustment as why you can't get a hard lever , brake drum worn out or what ever

 

[Goober]

I don't have that in mine

Removing that seal just prevents further obstruction of those holes. This is my 93. You don’t have the seal so don’t remove it. ?
You have air trapped in the top of the brake line just beyond the mc—just lightly thump the brake lines with your fingers to get those bubbles up to the mc, then jiggle the mc piston to get them out. If you don’t see any bubbles at all then air still trapped.

 

[cmanningjr]

Did you adjust your brake shoes out after you installed the drum? 99.9% of everyone that does brakes on these don’t do that.. there’s very little travel in the pistons. So, adjust your brakes out to where they are touching the drum, then back off a hair.. let us know how it goes


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[09z71]

You've done the conversion with stock 11s? Did you have to do anything different?? This might be the route I go.


Yes I adjusted the pistons so I can barly fit the drum over.

 

[fishfiles]

You've done the conversion with stock 11s? Did you have to do anything different?? This might be the route I go.


Yes I adjusted the pistons so I can barly fit the drum over.

No , 11 inch rims won't work , you need 12 inch rims --------------- you need to adjust the brakes after the drum is on , not before the drum is on so it barely fits

 

[09z71]

You've done the conversion with stock 11s? Did you have to do anything different?? This might be the route I go.


Yes I adjusted the pistons so I can barly fit the drum over.

No , 11 inch rims won't work , you need 12 inch rims --------------- you need to adjust the brakes after the drum is on , not before the drum is on so it barely fits

Cool I'll give that a shot.

Your blue 300 is awesome btw. Here's mine

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[fishfiles]

Thanks ! I had no clue you were a Brother Blue , guess you would be my older brother as you got me by a year with the 1991 ... blue has become my favorite and I was always a hard core " ride red " guy ---- I like where you mounted your led light , I might be able to do that on Ol'Blue -------------- can you snap a pic of your mount ? ------------

 

[09z71]

Thanks ! I had no clue you were a Brother Blue , guess you would be my older brother as you got me by a year with the 1991 ... blue has become my favorite and I was always a hard core " ride red " guy ---- I like where you mounted your led light , I might be able to do that on Ol'Blue -------------- can you snap a pic of your mount ? ------------

Yes sir. I'll snap one when I get home.its pretty nice

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[09z71]

Well sob....I adjusted them with the drums on and they work like a charm.

I feel like an idiot. Thanks guys.

Here's that pic of the mount

And here is a link.

https://rover.ebay.com/rover/0/0/0?mpre=https://www.ebay.com/ulk/itm/152808399220

Pretty nifty mount. I'm a huge fan of handlebar mounted lights. My first atv was a trx125. Loved it.

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[fishfiles]

Wow , check them brackets out , never seen them before , your light looks good and the light follows where you turn

 

[09z71]

Wow , check them brackets out , never seen them before , your light looks good and the light follows where you turn

I use to be real big into rock crawling and building crawlers with my buddies. These mounts are to mount lights on roll bars. I figured I could use the same type on a 7/8" handlebar. Works like a champ.

I also made my own winch plate. It's just a piece of 1/4" plate that is u bolted to the frame. Fairlead is bolted to the grill guard.

Added a usb charging port too.


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[fishfiles]

Homemade 1st gen winch plate, that bolts up and is not welded to the frame , you say !!!! ----I am in the need of one of those , started making one and never did get back to it , can you snap a pic of your winch bracket ?

 

[09z71]

I just cut it to match the bottom of the winch and to sit down on the tube. 4 u bolts and 2 grade 8 bolts ftw. It's been used abused and hasn't moved or broken anything haha

I might have to start a thread about this bad boy.

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[fishfiles]

Looks great ! -- I am doing it a little different , I am u-bolting to the frame and trying to stay off the front bumper , ii will most likely be alright to the bumper , I have had the winch bolt to the top of the front rack before and never bent it

 

[09z71]

Nice.

These first gens are something else. Finding parts is ridiculous. But they're unique...especially the blue ones. You don't see them often


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[fishfiles]

'Z71 , you are right , the 1st gen blue is getting rare , and 1st gen parts are getting hard to find ---- after looking at your winch plate again , which you done really nice job on , I am thinking of scraping what I got so far and doing the same as you , if I get two u-bolts to the main frame and two to the front bumper I think it will be fine , I was really scared of bending up the bumper , and don't want to weld the plate to the frame like most people seem to do

how are you going to control your winch . With a rocker switch and solenoid or a wireless remote ? ---- from my experiences , I would stay away from the wireless remote , I have had them engage and not let off , it kept going on it's own till I disconnected the cable , I think what happened to me was the winch was in the wind mode and the battery went dead so it just kept on winding ,

 

[09z71]

So those pics are from when I fabbed up the plate, roughly 7 months ago. It has been mounted and I've been using it. I bought the harbor freight winch and it came with a wireless remote. I haven't had any issues yet.

Friend of mine has the same winch mounted on his 06 honda with a rocker switch mounted next to his light switches. Seems to work fine for him.

Where did you mount your control box?

I originally bought this because I wanted a pos that ran great. Something i wouldn't be scared to really dog. So the plastics aren't the greatest. So I mounted mine directly to my front plastics.

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