Polaris Ranger 500 2x4 2007 Service Manual page 269

BRAKES
MASTER CYLINDER
Removal
1. Open the hood. Locate the master cylinder.
2. Remove the nut and bolt (A) from the brake pedal.
9-13 ft. lbs.
A
(12-18 Nm)
20-22 ft. lbs.
B
(27-30 Nm)
3. Place a container to catch brake fluid under the master
cylinder brake line banjo bolts (B).
NOTE: Dispose of brake fluid properly and do not
re-use.
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
4. Loosen the banjo bolts (B) for the brake lines and allow
fluid to drain.
NOTE: Make note of front and rear brake line
locations to master cylinder.
5. Remove the two mounting bolts (C) that secure the master
cylinder to the frame.
Installation
1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
After installing the foot brake check pedal freeplay. Pedal
freeplay should not exceed .090" (2.286 mm).
9.6
C
A
CAUTION
FOOT BRAKE PEDAL
Pedal Removal
1. Open the hood. Locate the master cylinder.
2. Remove the nut, bushing, tube, and bolt from the brake
pedal.
Master Cylinder
Tube
Nut
Bushing
9-13 ft. lbs.
(12-18 Nm)
3. Remove the clevis pin and cotter key from the master
cylinder to remove the brake pedal.
Pedal Installation
1. Reverse Steps 1-3 for foot brake installation. Torque the
clevis nut to 9-13 ft. lbs. (12-18 Nm). After installing the
foot brake check pedal freeplay. Pedal freeplay should not
exceed .090" (2.28 mm).
Brake Pedal Freeplay:
.090" (2.28 mm)
Bolt
Bushing
Clevis Pin
Cotter
Brake Pedal
Key