Brake Line Replacement - Polaris 600 RUSH 2010 Manual

Final Drive/Brake System

Brake Line Replacement

BRAKE HOSE FITTING
BRAKE SWITCH
COMBINED MASTER CYLINDER SHOWN
Follow these steps if the brake line is to be replaced.
1. Drain the brake system by attaching a clear hose to
the caliper bleed fitting.
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.
Remove the brake line from the caliper assembly. Use
a shop towel to catch any remaining brake fluid in the
hose.
5. On Cyclone master cylinders, remove the banjo bolt,
washers and fitting from reservoir.
6. On combined master cylinder, 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.
8. Unplug the brake light switch harness from the master
cylinder.
9. Remove the brake line from the master cylinder.
5.24
10. Install new brake line on caliper and orientate it as
noted in step 4.
Brake Caliper Banjo Bolt:
240-264 in-lbs (27-30Nm)
11. Insert the new brake line and install into the master
cylinder. Torque the brake line to specification.
Brake Line-to-Master Cylinder:
240-264 in-lbs (27-30Nm)
12. 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.
13. Route the brake light switch in the harness correctly.
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