Foot Brake Master Cylinder; Foot Master Cylinder Removal / Installation; Brake Pedal Removal / Installation - Polaris 2009 Sportsman XP 850 Service Manual

FOOT BRAKE MASTER CYLINDER

Operation Overview
When the brake pedal is applied it contacts the piston of the foot
brake master cylinder. As the pressure within the system is
increased, the pistons located in the rear brake calipers move
outward and apply equal pressure to the brake pads.

Foot Master Cylinder Removal / Installation

1. Remove the RH mud guard and footwell (see Chapter 9).
2. Remove the front and rear brake line from the master
cylinder. Use a suitable container to catch the brake fluid.
Dispose of brake fluid properly.
3. Remove the (2) through-bolts retaining the master cylinder
to the mount bracket. Replace components as needed.
4. Reverse this procedure when reinstalling and torque
mounting fasteners to specification.
Master Cylinder Mounting Fasteners:
8 ft. lbs. (11 Nm)
5. Reinstall the brake line and torque the banjo bolt (with new
sealing washers installed) to specification.
Brake Line Banjo Bolts:
15 ft. lbs. (20 Nm)
6. Bleed the master cylinder following the procedure outlined
in the "Brake Bleeding" section of this chapter.

Brake Pedal Removal / Installation

1. Remove the RH mud guard and footwell (see Chapter 9).
2. Remove the through-bolt retaining the brake pedal to the
mount bracket.
3. Remove the bolt, bushings, spacer, spring and brake lever.
4. Inspect and replace components as needed.
5. Reverse this procedure when reinstalling and torque
mounting fastener to specification.
Brake Pedal Mounting Fastener:
38 ft. lbs. (52 Nm)
BRAKES
= T
= T
= T
11.9
11