Rear Brake Pedal - Polaris 1999 Sportsman 400 Service Manual

BRAKES
2
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1
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3
REAR BRAKE PEDAL 11996.1997)
415
1. Cotter pin
2. Washer
3. Linkage rod
4. Clevis pin
5. Cotter pin
2. Rem ove the rear ca liper as de scribed in thi s
chapter.
3A. On 1996-1997 mode ls, perform the following:
a. Disconnect the output shaft caliper brake
hose fitting from the left side outlet on the
four-way connector.
b. Disconnect the brake hose from the out put
shaft caliper fitting.
3B. On I998-on models, perform the followi ng:
a. Disconnect the output sha ft ca lipe r front
brake hose fitt ing from the left side out let on
the four-way connector
(C,
Figure 75).
b. Disconnect the fr ont brake hose from the out -
put shan ca liper fin ing (A , Figure 77 ).
c. Disconnect the rear brake hose fitting from
the rear mas ter cylinder fitting (F igu re 7M).
d. Disconn ect the rear brak e hose from the out-
put shaft caliper fitting (B, Fig u re 77) .
4. Place theend of the brake hosesover a container
and let thebrake fluid drain out into the container.
5. Remove any tic wrapssecuring the brake hose(s)
to the chassis.
6. Note the routi ng of the brake hose(s) through the
frame. T he brake hosc(s) must follow the exac t
6. Spring
7. Washer
8. Brake pedal
9. Washer
10. Bushing
same path w hen installed to avoid any kinks or
damage.
7. Install new hosc(s) in the reverse order of
rc-
moval whi le noting the following:
a. Tig hte n the brake hose fittings secu re ly.
b. Refill the front and rear master cy linder reser-
voirs a nd bleed the front and rear brake sys-
tem as described under Bleeding the System in
this chapter.
REAR BRAKE PEDAL
Removal/Instal latinn
(1996-1997 Models)
Refe r to Figure 79.
I . Rem ove the rear fender and the rig ht-side
footwell as desc ribed in Chapter Fifteen.
2. Remove the co tter pin and withdraw the clevis
pin from linkage rod.
3. Disconnect the linkage rod from the brake pedal.
4 . \Vorking under the frame. remove the co tter pin
and washer securing the brake pedal to the pivot
point of the fram e.