Front Master Cylinder Removal/Installation - Polaris 1999 Sportsman 400 Service Manual

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3. lnstall a new piston seal (B,
Fi~ure
48) into the
inner groove in the cylinder bore of eac h caliper.
4. Install a new dust seal (A, Figure 48 ) into the
outergroove in the cylinder bore of each caliper.
NOTE
Check that the sea ls
fit
sq uarely into
tire cylinder bore glv ol'e.
If
a seal is
not installed properly, the caliper as-
semblv will leak and braking pe rfor-
manee will be reduced.
5. Position the piston with the smaller closed end
going in first (Figu re 56) and install the piston into
the cylinder bore. Push the piston in until
it
bot toms
(Figu re 57 ).
6. Repeat for the othcr piston .
7. lnstall ncw O-ring seals (Figure 58 ) into the re-
ceptac le in the outboard caliper hair.
8. If remo ved. install the locating pin (Figure 59).
Push it in until it bottom s.
9. Asse mble the two caliper hal ves toge ther (Fig-
ure 60) and make sure the locating pin and both
small O-ring seals arc stil l located correctly.
10. Insta ll the Allen bolt (Figure 46) securing the
caliper halves together. Finger tighten the bolt at
this time . Alte r the caliper has been installed,
tighten the Allen bolt to the torque specification
listed in Tahle 2.
II . Install the brake calip er assembly as described
in this chapter.
F1tO{';T MASTER CYU {';DEI{
Removul/l nsta lIatiun
I. Park
the vehicle on level ground and block the
wheels so the vehicle cannot roll in either direction.
2. Co ver the area under the master cy linder.
®
CHAPTER FOU trfEEN
CAUTION
tf
brake
fluid
should contact an}"
SIII"-
face. wash the area immediatel y
with
soapy wale,. ami rinse completely.
Brake fluid will damage plastic,
pa inted and plated s urf aces.
3. Loosen the clamp bolts (Figu re 61) secur ing the
master cy linder to the handlebar.
4. Clean the top o f the master cylinder ofall debris.
5. Remo ve
the screws securing the top cov er (A .
Figure 62).