Combined Master Cylinder/Lever Service; Cyclone Master Cylinder/Lever Service - Polaris 600 RUSH 2010 Manual

Combined Master Cylinder/Lever Service

BRAKE LEVER
Switch Pack Screw Location/Torque Sequence:
#10x.75 SCREWS
#10x1.12 SCREW
#10x1.5 SCREW
Torque upper two screws until gap is closed.
Torque bottom two screws to specification.
Test MODE/SET switch for binding.
If switch binds, loosen bottom two screws evenly
until binding stops. Maintain a closed gap at the top.
Cover Screws: 16-20 in-lbs (1.8-2.3Nm)
Switch Pack Screws: 25-30 in-lbs (2.8-3.4Nm)
Brake Hose: 240-264 in-lbs (27-30Nm)
1. To remove the brake lever, remove the e clip from the
lever pin.
2. Extract the pin from the housing, then remove the
lever.
3. To remove the parking brake lever, the housing cover
must be removed. Once removed, carefully extract
the spring noting it its position inside the housing.
COVER SCREWS
COVER
PARKING BRAKE LEVER
LEVER PIN
SWITCH
CARTRIDGE
E CLIP
TOP
1 2
3
4
TORQUE SEQUENCE
= T
Final Drive/Brake System
Remove the parking brake lever.
4. To remove the cartridge, completely drain the brake
fluid from the housing. Remove the brake and parking
brake levers.
5. Disconnect the brake hose from the cartridge.
Carefully pop the cartridge out of the housing.
6. To install the cartridge, lubricate the entire surface
with DOT 4 brake fluid.
7. Align the cartridge with the housing tabs, then firmly
press the cartridge back into the housing until the
cartridge is engaged with the tabs.
8. Refill and bleed the brakes system as outlined in this
chapter. See "Brake Fluid Replacement & Bleeding"
on page 5.22.
9. Test brake system prior to returning vehicle to service.

Cyclone Master Cylinder/Lever Service

COVER SCREWS
COVER
LEVER PIN
BRAKE SWITCH
PARKING BRAKE LEVER
Cover Screws: 6-8 in-lbs (.7-.9Nm)
Handlebar Clamp Screws: 60-80 in-lbs (6.8-9Nm)
Brake Hose Banjo Screw: 240-264 in-lbs (27-30Nm)
CLAMP SCREWS
CLAMP
E CLIP
BRAKE LEVER
E CLIP
= T
5.23
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