Hand Brake Master Cylinder; Removal; Disassembly; Installation - Polaris Sportsman 850 Service Manual

BRAKE SYSTEM

HAND BRAKE MASTER CYLINDER

REMOVAL

1. Clean master cylinder and reservoir assembly. Make
sure you have a clean work area to disassemble
brake components.
2. Place a shop towel or suitable catch container under
the master cylinder brake line connection. Remove
the banjo bolt fitting that connects the brake line to
the master cylinder. Discard the sealing washers.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished
surfaces.
3. Remove the Torx screws from the master cylinder
clamp.
4. Hold master cylinder upright and lift the master
cylinder from the handlebars. Cover brake line orifice
to avoid spilling fluid.
9.14

DISASSEMBLY

The hand master cylinder is a serviceable component.
Polaris offers a number of service kits to rebuild this style
of master cylinder. Refer to the Polaris Electronic Parts
Catalog.

INSTALLATION

Use only OEM parts that were designed for the model
ATV being serviced. There are different hand master
cylinders for the different Polaris ATV models. Refer to
the Electronic Parts Catalog.
Some master cylinders are not serviceable and are
replaced only as an assembly.
1. Install master cylinder on handlebars. Torque bolt
furthest from the reservoir first, followed by the bolt
closest to the reservoir. Torque clamp bolts to
specification.
TORQUE
Clamp Bolts:
70 in. lbs (8 Nm)
2. Place new sealing washers on each side of banjo
line and torque banjo bolt to specification.
Speed up brake bleeding by purging air before brake
line is attached. Fill with DOT 4 Brake Fluid and pump
lever slowly 2 to 3 times with finger over the outlet end
to purge master cylinder of air.
TORQUE
Brake Line Banjo Bolt:
15 ft. lbs (20 Nm)
3. Fill reservoir with DOT 4 brake fluid (PN 2872189).
NOTE
NOTE