Polaris 1999 Sportsman 400 Service Manual page 415

BRAKES
b. Push the piston asse mbly on, hold it there and
install the new dust seal. Make sure the dust
sea l is co rrectly sea ted in the gro ove. Pus h on
the piston: it should spr ing back against the
dust seal.
413. On I999-on models, install the spring and the
piston into the master cylinder bore.
5. On 1999-on models, if the reservo ir was re-
moved, perform the following:
a. Make sure the matin g surfaces of the bod y
and reservoir are clean.
b. Install a new reservoir seal and apply fresh
brake fluid to the sea l.
c. Correctly position the reservoir onto the bod y
making sure the sea l is seating correctly onto
both parts.
d. Hnld both parts together and install both
mo unting screws. Tighten the screws eve nly
and securely- do not overtighten or the
threads will be stripped out of the rese rvoir.
6. Install the hand lever, bolt and nul. Tighten the
bolt and nut securely, then make sure the hand lever
operates freely within the master cy linder. There
should bc no binding.
7. Install the diaphra gm, cover and screws. Tighten
the screws only finger-tight at this time.
8. Install the master cylinder as describ ed in this
chapter.
REAR MASTER CYLINDER
NOTE
The /996- /997 models are
11 0 1
equipped with a rear master cylinder:
The outp ut
shaft
caliper is either con -
trolled hvdraulicallv bv thef ront mas-
ter cylinder or mechanicall y by the
rear brake pedal.
409
Removal/Installatio n
()998 Models)
Refer to Figu re 68.
1.
Park the vehicle on level ground and block the
wheels so the vehicle can not roll in either di rection.
2. Remove the sea t as describ ed in Chapter Fifteen.
3. Remove the front and rear fenders as described
in Chapter Fifteen .
4. If not removed during rear fender remo val, re-
move the right-side foot we ll.
5. Cove r the area under the rear master cylinder.
6. Remove the- cotter pin and clevis pivot pin sec ur-
ing the plunge r to the linkage.
7. Disconnect the reservoir hose from the maste r
cyli nder,
8. Loose n the reservo ir cap and drain thc brake
fluid into a container.
9. Place the loose end of the reservoir hose in a
reclosable plastic bag and sea l it to prevent contami-
nation and the discharge of brake fluid. Secure the
hose to the frame in the upright position.
10. Remove the bo lts and nuts securing the master
cylinder to the frame bracket.
II. Part ially remove the master cy linder
from
the
frame.
12. Unscrew the brake hose fitting from the master
cylinder. Plug the hose fitting on the master cylinder
to prevent the dripping of brake tluid.
13. Place the loose end of the brake hose in a
reclosable plastic hag and sea l it to prevent contami-
nation and the d ischarge of brake fluid. Secure the
hose to the frame in the upright position.
14. Remove the master cylinder from the frame.
IS. If necessary. remove the bolt and nut securing
the reservoir to the frame mountin g bracket. Re-
move the reservoir and hose from the frame.
16. Install by reversing these removal steps while
noting the following:
a. Install the brake line to the master cylinder
and tighten securely.
b. Tighten the master cy linder mounting bolts
secure ly.
c. Refill the master cylinder with DOT 3 brake
tluid and bleed the brake as described in this
chapter.
WARNING
Do not ride the vehicle until the
brakes are working proper ly.
Malee
sure that the brake lever travel is not