BRAKES
9.9
2. Place a shop towel under brake line connection at
master cylinder. Loosen banjo bolt; remove bolt
and sealing washers.
CAUTION:
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces.
3. Remove master cylinder from handlebars.
4. Hold brake upright and continue to remove
master cylinder. Cover brake line to avoid
spillage.
MASTER CYLINDER
INSTALLA
TION
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct
parts. There are different brake master cylinders for
the different Polaris ATV models. Refer to your parts
manual or guide for the correct parts.
This master
cylinder is not servicable and is replaced as a
unit.
1. Install master cylinder on handlebars. Torque
mounting bolts to 25 in. lbs. (3 Nm). Torque the
inside bolt first as indicated in the illustration tothe
right.
Torque both bolts to
25 in.lbs. (3 Nm)
Torque this 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 DOT3 Brake Fluid (PN
2870990) and pump lever slowly two to three times
with finger over the outlet end to purgemaster cylinder
of air.
2. Place new sealing washers on each side of banjo
line and torque banjo bolt to specification.
Brake Line
Banjo Bolt
Sealing Washers
Torque to 15 ft.lbs.
(21 Nm)
Master Cylinder Mounting Bolt
Torque 25 in. lbs. (3 Nm)
Brake Line Banjo Bolt Torque
15 ft. lbs. (21 Nm)
3. Fill reservoir with DOT3 Brake Fluid (PN
2870990).
Polaris DOT 3 Brake Fluid
(PN 2870990)
4. Follow bleeding procedure on Pages 9.7-9.8.
Check all connections for leaks and repair if
necessary.
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