ATV Brake is locked up

[Dannmann801]

Went to take my ATV out for a little spin yesterday - last time I used it was at the Mingo summer shoot.
(After that gig I brought it home, washed it real good, then took it out for a spin around the neighborhood.
Parked it in the garage and haven't moved it since.) It started right up, but when I put it in reverse it just locked up, no movement at all, brake is locked up and both the handlebar brake and the foot brake are froze solid too. So I took off the tire and banged it with a rubber mallet, to no avail.

Any advice? Should I just go ahead and tear into it? I've got a fair mechanical aptitude and have replaced drum brakes before, but it's not my strongest suit. I wouldn't mind just taking it to the dealer and having the brakes worked over, but I can't even move it to get it on the trailer.

What a pain in the balls.

Here's the picture:

http://s801.photobucket.com/user/dannmann801/media/atv brake 1_zpszpsa9tax.jpg.html?sort=3&o=0

 

[giles]

Did you just wash the plastics? That doesn't look very clean to me. Soak it with whatever your choice of penetrating oil is, then repeat this process at least once a day for a week. Then try the brakes again. I wouldn't buy any parts at this point, just let the oil do its job for a week or so.

 

[CJD3]

So it is the brake that's froze up and not a problem with the cables?
Do you use a "parking brake"?

 

[cotty16]

My old big bear used to lock up like that, especially in the winter. Water would get in the drum and freeze. If you have drum brakes, maybe pads rusted?

 

[Milo]

Dan, it's not a space shuttle or heart surgery so open the bitch up and let's see what happening

 

[Fluteman]

Those drum brakes are terrible about locking up. I've rebuilt several. See if you can pry back on the lever circled, where the cables are connected. If you can free it up, that will allow you to take the brake assembly apart. My guess is the seal around the cam (attached to the lever circled), the o ring for the cover, or the seal for the cover on the shaft is bad. Either way, water is getting in there, and that's why they are locked up.


I also attached an exploded pic of a typical atv brake hub assembly. Don't remember which atv you have, but do a Google search for "ATV OEM Parts Finder" and then look up your machine.

 

[hickslawns]

You got this Dan. I am with these guys. Hit the thing with some WD40 or PB Blaster type penatrating oil. Then work that lever where your cables come in back and forth. If you can take the cables off at the high end and get some lubricating fluid in there it will rule out the brake cables and work it's way thru them as you are messing with this.

 

[xbowguy]

Yep, check cables first. That is my experience.

 

[Bigslam51]

Just beat it with a hammer

 

[Dannmann801]

I just soaked it in wd40 and I'm going to tear it apart tomorrow nite. I'll call the Kawasaki dealer tomorrow and see what they have to say about parts and about their leadtime if I can get the thing freed up so I can transport it. We'll see how it goes. y'all are right, it ain't rocket science. just gotta give it a shot.

 

[Fluteman]

Those drum brakes are terrible about locking up. I've rebuilt several. See if you can pry back on the lever circled, where the cables are connected. If you can free it up, that will allow you to take the brake assembly apart. My guess is the seal around the cam (attached to the lever circled), the o ring for the cover, or the seal for the cover on the shaft is bad. Either way, water is getting in there, and that's why they are locked up.


I also attached an exploded pic of a typical atv brake hub assembly. Don't remember which atv you have, but do a Google search for "ATV OEM Parts Finder" and then look up your machine.
View attachment 37529View attachment 37530

Also, loosen the wing nuts on the cables and see if that frees up the brakes. If so, it is definitely a cable.

 

[hickslawns]

Check out Rocky Mountain ATV for parts. Dealer will stroke you pretty good most times. Slap some new shoes on there, clean the drums up, lube the cables, and you are good to go. These are not difficult. Drum brakes on cars sometimes make people nervous. Quad drums are easier.

 

["J"]

I wonder if they sell an aftermarket disc brake kit? If the drums are prone too issues would discs be the way too go?

Just curious....

 

[Fluteman]

I wonder if they sell an aftermarket disc brake kit? If the drums are prone too issues would discs be the way too go?

Just curious....

Discs are the way to go, but I've never seen a conversion kit for one. Downside to discs on a atv that sees mud is it will eat the brakes though, but they are cheap and easy to replace.

 

[5Cent]

Agreed with H2O in the "sealed" rear drums. There is a drain on each, anytime you go through water like we did, it is recommended to open and make sure they are dry. Good luck on the repairs Danno, you got this!

 

[Dannmann801]

Progress - took outer hub off, took shield around drum casing off, and started on the screws around the outside of the drum casing. They're phillips heads - 3 came off and 3 are starting to strip (I quit while ahead). I'm gonna hafta use some kind of extractor I think.

I also loosened the cables and took the hammer to that bracket, got it to move about 3/4" back and forth.

Any screw extraction hints?

 

["J"]

Take a hammer and smack the shit outta the tops of the screws.... Like pounding in a nail.... See if that helps Dan....

If not they sell an extractor that has two bits, one for taking out the screw cross point and the other for removing the screw like an easy out.... Both fit in the electric drill.....

I've got a cheaper set that works on easy ones, haven't tried it on harder too remove screws.....

 

[hickslawns]

What J said. Solid smack to them helps break the rust and dirt leghold.

 

[Buckmaster]

I'm a little late to the party. When my Polaris brakes "hang up" I simply put the bike in reverse and jam on the brakes. That typically frees up my stuck caliper.
Its never been more than that.

 

[Dannmann801]

I'd put the bike in reverse and gunned the engine, bike bucks toward the stuck brake.

I'm feeling pretty good about it. Talked to the dealer yesterday and they gave me some tips and said they can get parts in a day if not in stock.
Not gonna rush. Tonights goal is to get the three screws extracted.
Here's a link to my photobucket page showing all the pics I took as I was moving along
http://s801.photobucket.com/user/dannmann801/library/?sort=3&page=1