6.23
Drive and Brake Systems
6
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
4. Hold the caliper over the brake fluid jar and then push
the pistons back into the caliper. This will push the
brake fluid in the caliper out of the brake hose banjo
fitting hole.
5. Clamp the end of a 1/4” thick 2” x 10” piece of steel to
the workbench. Allow the piece of steel to hang off of
the bench by 4 - 5”.
6. Position the caliper over the steel plate with the plate
firmly against one of the retracted pistons.
7. Insert a rubber-tipped air nozzle into the brake hose
inlet port and apply compressed air to push out the
piston.
8. To remove the second piston, lay a rubber sheet on
the steel plate and position the caliper over the rubber
sheet to seal the open piston bore. Repeat STEP 7.
9. Using a plastic or wood pick, remove both piston seals
from the caliper bores. Discard the seals.
10. Clean the caliper and pistons with denatured alcohol
and dry with either compressed air or a lint-free rag.
11. Inspect the caliper bores and pistons for pitting, heavy
scoring or corrosion. Replace parts if heavily scored
or pitted.
12. To assemble the caliper, lubricate two new piston
seals with new brake fluid. Install each seal by
inserting one point of the seal into the bore groove,
and then work the seal around the groove with your
index finger. Do not twist, or rip the seals.
13. Coat the piston thoroughly with new brake fluid.
Evenly insert each piston into the bores, working each
in by hand carefully and slowly. Push each piston
down until bottomed out.
14. Reinstall the brake caliper on to the chaincase.
Torque fasteners to specification.
15. Inspect both brake pads prior to installation. If they are
within the pad wear specification, reinstall into caliper.
16. Install the brake hose using the same routing and
orientation noted during removal. Torque fitting to
specification.
17. If the caliper is liquid-cooled, reinstall the cooling
hoses. Bleed the cooling system after bleeding the
brake system if required.
18. Fill and bleed the brake system of air. See “Brake
Fluid Replacement & Bleeding” on page 6.20.
19. Test the snowmobile at low speed to verify operation.
Brake Disc Replacement
The brake disc must be replaced if the thickness of the disc
is below .193"(.49cm) or if the disc is warped.
1. Remove the brake pads from the brake caliper.
Remove the brake caliper from the chaincase.
2. Do not let the brake caliper hang from the brake hose.
Tie it up to the steering hoop or console.
3. Remove the chaincase from the bulkhead.
4. Remove the o-ring from the jackshaft and discard.
Slide the brake disc off of the jackshaft.
5. Check the jackshaft for any damage.
6. Replace the o-ring on the jackshaft.
7. Replace the brake disc. Assemble the chaincase and
re-mount the brake caliper.
DO NOT PUSH ON THE CALIBER BORE PLUG.
DOING SO WILL BREAK THE PLUG SEAL AND
REQUIRE CALIPER REPLACEMENT.
TO AVOID POSSIBLE INJURY, DO NOT PLACE
FINGERS BETWEEN PISTONS TO ATTEMPT TO
CATCH THEM WHEN APPLYING COMPRESSED
AIR.
WEAR EYE PROTECTION WHEN APPLYING
COMPRESSED AIR TO CALIPER.
Caliper Mounting Screws: 18-20 ft-lb (24-27 N-m)
Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m)
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