Brake Light Switch Replacement; Caliper; Caliper Removal - Polaris 340 CLASSIC 2006 Manual

BRAKES
2. Attach the other end to a Mity Vac or similar vacuum tool.
3. Bleed the system of brake fluid.
4. Note the orientation of the brake line. The brake line will
need to be replaced in the same orientation.
5. Remove the brake line from the caliper. Cap or cover the
end to catch any brake fluid that may still be in the line.
6. Loosen the brake line from the master cylinder 1/4 to 1/2
turn.
7. Remove the 4 screws that hold the master cylinder to the
handlebar. This will separate the master cylinder from the
switch pack.
168-216in-lb(18.9-24.4Nm)
8. Unplug the brake light switch harness from the master
cylinder.
9. Remove the brake line from the master cylinder.
10. Install new brake line on caliper and orientate it as noted
in step 4.
11. Torque the caliper banjo bolt to 168-216 in-lb (18.9-
24.4Nm).
12. Insert the new brake line and install into the master
cylinder. Torque the brake line to 144-192 in-lb (16.2-
21.6Nm).
13. Tighten the brake line into the master cylinder in an
orientation so that the line does not have any sharp bends
when it is installed on the handlebar.
14. Route the brake light switch in the harness correctly.
15. Place the switch pack with the master cylinder onto the
handle bar. Two smaller screws should be placed on the
top and the longest screw is placed on the lower right.
16. Follow the bleeding procedure as outlined in "BRAKE
9.4
FLUID REPLACEMENT & BLEEDING" on page 9.3.
500 INDY, 340 Classic, 550 Classic, 340 Touring, Trail Touring,Trail Touring Deluxe

BRAKE LIGHT SWITCH REPLACEMENT

1. Remove the 4 screws that hold the master cylinder to the
handlebar. This will separate the master cylinder from the
switch pack.
2. Unplug the brake light switch harness from the master
cylinder.
3. Unplug the brake light switch from the master cylinder.
4. Replace faulty brake light switch into the master cylinder
and route wires correctly.
5. Plug the brake switch back into the harness.
6. Replace the master cylinder to the switch pack and insert
the smaller screws on the top, the longest one goes into the
lower right side.

CALIPER

CALIPER REMOVAL

1. Remove the two caliper bolts that hold the caliper to the
chaincase.
2. Remove the caliper from the brake disc.