Polaris Outlaw 500 - Installation

6.11
BRAKES
6
4. Remove master cylinder from handlebars.
Installation
1. Install master cylinder on handlebars. Torque mounting
bolts to 85 in. lbs. (9.6 Nm). Torque the top bolt first.
NOTE: To speed up the brake bleeding procedure
the master cylinder can be purged of air before
brake line is attached. Fill with DOT 3 or DOT 4 Brake
Fluid and pump lever slowly two to three times with
finger over the outlet end to purge master cylinder of
air.
2. Place new sealing washers on each side of banjo brake line.
Install the brake line into the master cylinder. Torque the
brake switch bolt to 15 ft.lbs. (20 Nm).
Master Cylinder
Front Brake Line
Caliper
Banjo Bolt
Banjo Bolt
Retainer
Caliper
Mount Bolt
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
18 ft. lbs.
(24 Nm)
Master Cylinder Assembly
Cover Screws
Clamp Bolts
85 in. lbs. (9.6 Nm)
11 in. lbs. (1.24 Nm)
Banjo Bolt
15 ft. lbs. (20 Nm)
Master Cylinder Mounting Clamp
Bolt Torque: 85 in. lbs. (9.6 Nm)
Banjo Bolt Torque:
15 ft. lbs. (20 Nm)
15 ft. lbs.
85 in. lbs.
(20 Nm)
(9.6 Nm)
Brake Line
Sealing Washers
Torque to 15 ft. lbs.
(20 Nm)