Polaris 1999 Sportsman 400 Service Manual page 422

416
5. Wit hd raw the b rake ped al from th e frame and re-
insta ll the was he r and co tte r pin onto the bra ke
ped al to avo id misp lac ing th em .
6. lf'nccessary, remove the bu sh ing fro m each side
of th e frame pivot po int.
7. To re move the linkage rod. rem ove the cotter pin
and d isco nnect the link ag e ro d from the caliper
brake arm.
8 . Insta ll
by
reve rsing th ese remo val steps while
noting the fo llowing :
a. Apply grease to all pivot po ints prior tn inst al-
lation.
b. ln stall ne w co ue r pin s and bend the ends over
completely.
Rernnval/Instal larlon
(199M Models)
Refer
L a Figure 6M.
I. Remove the rear fend er and the right-side
foo twe ll as described in C ha pter Fifteen .
2. To remo ve the brake peda l o nly, pe rform the fol-
low ing :
a . Rem o ve the co lter pin and cle vis pin se curing
the linkage rod to the br ake pedal.
b. Re move the co tter pin an d inner washer se-
curing the brok e peda l to the pivot po int of the
frame .
c . Withd raw the brak e peda l and o uter wa sher
from the fram e and rein stall the inner wa sher
and eot te r pin on to th e brake pedal to avoid
mispl acing the m.
d. Ins pect th e bushings w ithin the pivo t point on
the fram e; repla ce
if
worn or d am aged .
3. To
rem ove the linkage assem bly,
perform the
foll owing:
a . Disconnect the linkage rod from the brake
ped al as described in Step 2.
b. Re move the cott er pin and cle vis pin securing
the link age to the re ar master cy linder clevis.
c.
Remo ve th e
1\ \10
bo lts and nuts secu ring the
pivot mo unting plate to th e frame and remove
the assemb ly.
4. To
d isassemb le the pivot mo unting plat e and
link age,
perform
the following:
a. Remove the linka ge assembly
as
descr ibed in
Step 3.
b. Remove the bo lt se curing the lever
to
the
link age.
CHAPTE R FOU RT EEN
c. Rem ove the washe r, lever and wash er fro m
th e linkage.
d. Withdraw the linkage and wa she r fro m th e
pi vot mo unting pl ate.
e. Inspect the bushing s within the pivo t mount-
ing plate ; replace if wo rn or damaged .
5. Assem ble and insta ll by rever si ng th ese di sas-
sembly and remo val steps w hile no ting th e fo llow -
mg:
a. App ly g rea se to a ll pivot po ints prior to instal -
lati on.
b. Ins ta ll nell'
colter
pin s a nd be nd the end s over
com plete ly.
Rem oval /I nsta llation
( 1999-0 n M od els )
Refer
to
Fig ure
69.
I. Remove the rear fende r an d the rig ht-side
foot w ell as descri bed in C hap ter Fi ftee n.
2. Re move the cotter pin and was he r (A , Figure
HO) secur ing th e rear brake pedal to the
frame
pi vo t
s haft.
3. Wit hdraw the brake peda l (B, Figure 80) from
the frame pi vo t sha ft.
4 . Remove the washe r and spring fro m th e fra m e
pi vot shaft.
5. l f neccssa ry, remove the bu shin g
from
each s ide
o f the brake peda l pivot po int.
6.
Insta ll by rev er sin g
these
remo va l
steps while
noting the fo llow ing :
a . Ap ply gre ase to all pivot points pr ior to ins ta l-
lation .
b. Insta ll a
I/ el\'
cotter pin and bend th e ends over
co mplete ly.
c. Attach the spring to the bra ke peda l an d
frame.