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Discussion Starter · #1 ·
Okay i'm still working out all the kinks on this Foreman I traded for and the latest issue is the foot brake has started locking up. The first time I noticed it was yesterday, when I put it in gear and took off it was making a bad squealing noise. The foot pedal stays in the down position when I use it and I have to manually pull it back up. This is a new problem so any help would be appreciated. I took the drum off but nothing looks messed up, and I also loosened the hand adjustments but no help....
 

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If the back brakes shoes are worn a lot and the lever at the back brakes is adjusted up all the way, they will do that. You might need new brake shoes. If that isn't the problem, then I would say that your brake cable might need to be replaced.
 

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Discussion Starter · #3 ·
okay I haven't noticed the lever at the back brakes. There are two cables with wingnuts for adjustment, that is the only thing i've seen...How can you tell if the brake shoes are worn? They are thin, but can't tell if they are worn...I have another atv for parts so if the brake cable needs replaced I can rob one off the other bike....
 

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How far are the wing nuts tightned up the adjustment rod? And if the shoes look thin then I would replace them. You can take the cables loose from the arm and check to see if the arm moves freely without the cables attched. If it does it's more than likely your cables. if the arm is hard to move the shaft that goes into the drum may have to be cleaned. I have had this same problem and it was the arms shaft that was sticking.
 

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One of those cables is for the foot peddle, the other is the hand lever. If I'm not mistaken, the foot peddle is actually a shaft, but whatever, it won't matter.

You can test the cable theory by finding which one is for the hand lever, and loosen that wing nut. If the foot peddle still sticks then you can look at other causes.

Pop the drum off the wheel and make sure it's clean inside. Look at the brake pads and there should be more than 1/16 inch of pad left, as a guess. I think new the pad is probably about 1/8-3/16 inch thick.
 

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Discussion Starter · #6 ·
There is still a quarter of an inch of material on the shoes, although one is starting to flake off a little bit...both wingnuts were tightened up almost all the way...I will check more when I get off work this evening...
 

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If the nuts are all the way up that is not good. That means that the brakes are most likely engaged all the time you nedd to back them off to where the shoes make a strong contact but not so far as to not engage.

If someone on here can explain it better please do. My mind isn't working well this morning.:D
 

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I think you got it. Too tight = bad. Just tight enough = good. :)

The owners manual should have a page on how to adjust the brakes, and how much. It will say something like "adjust the brakes such that the brake lever is pulled back 3/4 inch when engaged", or something like that.
 

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Sounds like you guys have him covered.
 

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On my friends 400ex, it ended up being the foot brake arm. He replaced it and cleaned plus greased where it slides on and never has had a prob. with it again.
 

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On my friends 400ex, it ended up being the foot brake arm. He replaced it and cleaned plus greased where it slides on and never has had a prob. with it again.
Yeah, sometimes it can be the foot pedal. He could unhook the cable from the back brake lever and check it. If it still don't move free, then that is the problem.
 

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Discussion Starter · #12 ·
I took the cables off the arm in the back where it adjusts and the arm moves freely...The foot pedal is still sticky though, when I push it down I have to pull it back up by hand or it will stay in the down position...I put it all back together and the brakes aren't sticking, or at least aren't sounding like they are sticking so maybe its alright..The right handbrake is my next issue to tackle, I have to squeeze it about 3 times before it will gain pressure and stop the atv. I know the brakes are susceptible to mud and dirt, but I went through these front and rear, cleaned all the dirt out and made sure everything looked good..They work good enough I dont worry about it but it would be nice to get everything working right. Is there anything I can do other than keeping them cleaned to make everything work better...

I appreciate everybodys replies..As ya'll can probably tell i'm not much of a mechanic, but with some info to lead me in the right direction I can usually do some good...
 

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I took the cables off the arm in the back where it adjusts and the arm moves freely...The foot pedal is still sticky though, when I push it down I have to pull it back up by hand or it will stay in the down position...I put it all back together and the brakes aren't sticking, or at least aren't sounding like they are sticking so maybe its alright..The right handbrake is my next issue to tackle, I have to squeeze it about 3 times before it will gain pressure and stop the atv. I know the brakes are susceptible to mud and dirt, but I went through these front and rear, cleaned all the dirt out and made sure everything looked good..They work good enough I dont worry about it but it would be nice to get everything working right. Is there anything I can do other than keeping them cleaned to make everything work better...

I appreciate everybodys replies..As ya'll can probably tell i'm not much of a mechanic, but with some info to lead me in the right direction I can usually do some good...
I would take the brake pedal off and remove any rust with sandpaper and then grease the shaft that the pedal goes on. White lithium grease would be a good choice here, since it is waterproof.

Ok, the right lever controls the front brakes. Are your front brakes, disc or drum? I know you said it was a Foreman, but it depends on the year, as to which it has, disc or drum. If it has disc brakes, either your brake pads are worn out or your brakes have air in them and need to be bled. If it has drum brakes, either the shoes are worn out or the shoes need to be adjusted up or they may need to be bled. Oh, and be sure to check the brake fluid and make sure it isn't low, first.
 

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Discussion Starter · #14 ·
the front brakes are drums. We already adjusted them so that they rub slightly when the lever is engaged but i will look it all over again.. I dont remember what the shoes looked like on the front so when the rain quits i'll check it out. The foot pedal is the only thing I haven't taken off so I will do what you say and clean it up and grease it and see what that does..
 
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