Brake Caliper; Brake Pad Replacement; Caliper Removal / Installation; Brake Caliper Piston And Seal Replacement - Polaris 340 LX 2007 Service Manual

Drive and Brake Systems

BRAKE CALIPER

3
CALIPER
1
5

Brake Pad Replacement

NOTE: Always replace both brake
pads at the same time.
The brake pads must be replaced if the
thickness of the friction material is less
than 1/16" (1.6mm).
1. Rotate and remove the brake pad
retaining pin (3).
2. Remove the brake pads (4).
3. Inspect the brake disc (5) for any
wear.
4. To make room for the new pads,
the pistons must be pushed back into the caliper.
5. Clean any dirt from the master cylinder cover.
Remove the cover.
6. Insert two flat blade screwdrivers between one of the
pistons and the brake disc. Evenly pry against the disc
and the piston to push the piston back into the caliper.
7. Watch the brake fluid level in the master cylinder. The
fluid will rise as the pistons are pushed in. Remove
excess fluid and discard.
8. Install the new pads and install the new brake pad
retaining pin included with the new pads.
9. Actuate the brake lever several times to verify proper
operation.
10. Reinstall the master cylinder cover. Clean the caliper
assembly and master cylinder with a clean shop rag.
11. Test the snowmobile at low speed to verify operation.
6.22
4
BRAKE PADS
2
BRAKE DISC
Brake Pad
1/16" (1.6mm)
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.

Caliper Removal / Installation

1. Rotate and remove the brake pad retaining pin.
Remove both brake pads from the caliper.
2. Remove the two bolts that secure the caliper to the
chaincase.
3. Remove the caliper from the brake disc.
4. To install the caliper, re-mount the caliper around the
brake disc and align the mounting holes.
5. Install the caliper screws and torque to specification.
Caliper Mounting Screws: 18-20 ft-lb (24-27 N-m)

Brake Caliper Piston and Seal Replacement

CALIPER BORE PLUG
DO NOT PUSH OR MOVE!
PISTON SEAL
CAUTION
NEVER RE-USE PISTON SEALS. ALWAYS REPLACE
WITH NEW PARTS.
DO NOT ATTEMPT TO SAND OR POLISH A CALIPER
PISTON.
1. If the caliper is liquid-cooled, drain the cooling system
down enough to drain hoses attached to caliper, or
pinch inlet and outlet hoses.
2. Remove the brake hose from the caliper. Drain the
brake fluid into a jar or suitable container.
3. Rotate and remove the brake pad retaining pin and
then remove the brake pads. Remove the caliper from
the chaincase.
= T
PISTON SEAL
PISTONS