Auxiliary Brake Testing And Adjustment; Throttle Cable/Electronic Throttle Control Adjustment - Polaris 1999 Sportsman 400 Service Manual

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Chapter Fourteen. If tightening the connection does
not stop the leak or if the brake hose(s) is obviously
damaged, cracked or chafed, replace the brake
hose(s) and bleed the system as described in Chap-
ter
Fourt een .
Aux ilia ry Brake Testing and Adj ustm en t
(1996-1997 Models)
The auxiliary brake is intended for use as a
backup ifthe hydraulic system should fail. Depress-
ing the foot pedal on the right floor board aetivates
the rear brake, located on the transmission output
shall.
Testing
I . Shift the transmission into NEUTRAL.
2. Support the vehicle with the rear wheels otT the
ground. Block the front wheels so the vehicle can-
not roll in either direction.
3. Rotate the rear wheels by hand and depress the
auxiliary brake pedal.
4. The rear wheel should stop rotatin g when the
brake pedal has traveled midway between the
at-rest position and bottomin g out on the floor-
board.
5. If the rear wheel does not stop rotating within
this pedal travel, adj ust the auxiliary portion of the
rear brake.
6. Ifa dju stment is not neeessary, lower the vehicle.
Adj usting
I. Shift the transmission into NEUTRAL.
2. Support the vehicle with the rear wheels off the
ground. Block the front wheels so the vehicle can-
not roll in either direction.
3. Remove the bolts and washers sec uring the drive
chain guard and remove the ehain guard.
4. At the rear brake caliper, loosen the loeknut (A,
Figure 50).
5. Rotate the rear wheels by hand.
6. Turn the adjust bolt (B, Figure 50) cloc kwise
until the rear wheel rotation becomes difficult. then
stop.
7. Co ntinue to rotate the rear wheels nod tum the
adjust bolt (B, Figu r e 50) countercloekw ise and
have an assi stant apply the rear brake. When the
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brake pedal has traveled to the mid-way point stop
turning the adju st bolt. Tighten the locknut.
8. Once again rotate the rear wheels by hand and
apply the rear brake. The rear wheels should stop
once the rear brake pedal has traveled to the
mid-way point. Readj ust if necessary,
9. Tighten the loeknut (B, Figure 50) securely.
10. Install the drive chain guard and tighten the
bo lls sec urely.
11. Lower the vehicle and test drive
it
to make sure
the auxiliary brake is operating correc tly, A lso,
make sure the rearbrakeis not dragging. Readjust if
necessary.
T h ro tt le Cable/E lect ronic
T hro tt le Co ntrol Adj ust ment
All models req uire some throttle cable play to
prevent changes in the idle speed when the handle-
bar is
turned.
The reco mmended amount of cable
free play is 1.6111111 ( 1/16 in.) when measured at the