[BayanDundee]

Hi Guys,
I have only recently got a 2012 CF500-X5 that needs a bit of work.

Currently on the braking system, I have 2 master cylinders, 1 on the handlebars and 1 connected to the footbrake which also has a cable activation from the other side of the handlebars.

Following the plumbing I see that they are all connected, 2 front callipers and 1 rear, and all operate when using any of the braking mechanisms, even the front calliper has 2 pipes coming into it for a single piston.

 This doesn't seem right, would like to have front and rear braking systems independent of each other in case of line breakage or something similar.

Has anyone replaced the distribution blocks, and blocked extra junction holes to separate the breaking circuit?,
if so which circuit do you use for the front and which for the rear?,
guess the footbrake master has more volume to run the 2 front calliper and the hand operated master for the single larger rear. does this seem the best option?

Would appreciate any advice as this is my first 4wd ATV.

[NMKawierider]

There were two systems used. One had a front caliper with a single chamber with one set of lines going to then from a distribution valve and another older system with two lines going to the calipers. On the older system with the two-line front calipers, they are a dual-chambered system so even though you see two lines going in, they are going to separate chambers. The handle bar master only activates the front brakes through one set of those separate chambers where the rear brakes...well..the foot brake pressures not only the rear but the other two chambers in the front calipers making it apply pressure on all four...and it used the distribution valve for proper application. The system sucks to bleed. And if you wish to isolate the front from the rear, you would stop it at the distribution valve by either capping the incoming pressure or removing and capping on both sides, the lines going to the front calipers. It is unclear as to what effect this has on the rear master. Likely the same as the newer ones. Not good to do. Here is what the old system looked like:



OK, on yours which is the newer system and only one set of lines to the front calipers, you would have to remove and cap the line from the rear master on both ends to stop the fronts from being activated..however..the rear master is dual-chambered and the one for the front if capped off will over-pressure before the rear gets enough to stop you so...because it has no where to go...and that's a problem. Even if it didn't the rear having only one caliper would be weak and possibly dangerous without the assistance of the fronts. So my suggestion is to leave it alone and live with it.  

I think I have a system breakdown somewhere and if so I'll post it below.

[BayanDundee]

Thanks for that, I do see that there are 2 bleed nipples on the front calliper, they are not working, so will find out what they look like inside when I strip them down, does look to be overcomplicated.

I do see that the diagrams you posted were for the 800, have been struggling to find decent details or a manual, would appreciate it if you could let me know where you got these from.

If I find the callipers are stuffed and need replacing, do you know what years and models  I could use to replace them with that will bolt straight up and only have a single chamber and line for the front, would like to go to a less complicated system if possible, if callipers are useable, then will stick to the current system for now as you suggested.Thankyou

[NMKawierider]

Thanks for that, I do see that there are 2 bleed nipples on the front calliper, they are not working, so will find out what they look like inside when I strip them down, does look to be overcomplicated.

I do see that the diagrams you posted were for the 800, have been struggling to find decent details or a manual, would appreciate it if you could let me know where you got these from.

If I find the callipers are stuffed and need replacing, do you know what years and models  I could use to replace them with that will bolt straight up and only have a single chamber and line for the front, would like to go to a less complicated system if possible, if callipers are useable, then will stick to the current system for now as you suggested.Thankyou

I re-read your post and see yours is a 2012 so it should be like the first one instead of the second one. Sorry, so few of those first ones still around. I think all the 500s and 800s from 2012-2017 had the same parts in that system.. but go to any parts house and look them up to be sure. That's also where I got those diagrams a while back. I "might" have a service manual for the CF 500 that's of that period. If so I will PM you a link so you can download it.