Master Cylinder Removal; Master Cylinder Installation - Polaris A09BG50AA User Manual

BRAKES
MASTER CYLINDER
REMOVAL
1. Clean master cylinder and reservoir assembly.
Make sure you have a clean work area to
disassemble brake components.
2. Place a shop towel under brake line connection at
master cylinder. Loosen banjo bolt; remove bolt
and sealing washers.
CAUTION:
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces.
3. Remove master cylinder from handlebars.
4. Hold brake upright and continue to remove
master cylinder. Cover brake line to avoid spills.
MASTER CYLINDER
INSTALLATION
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct
parts. There are different brake master cylinders for
the different Polaris ATV models. Refer to your parts
manual or guide for the correct parts. The master
cylinder is not serviceable and is replaced as a
unit.
1. Install master cylinder on handlebars. Torque
clamp bolts to 25 in. lbs. (3 Nm). Torque the inside
bolt first as indicated in the illustration to the right.
9.8
5 in.lbs. (0.56 Nm)
Torque both bolts to
25 in.lbs. (3 Nm)
NOTE: To speed up the brake bleeding procedure,
the master cylinder can be purged of air before brake
line is attached. Fill with DOT3 Brake Fluid (PN
2870990) and pump lever slowly two to three times
with finger over the outlet end to purge master cylinder
of air.
2. Place new sealing washers on each side of banjo
line and torque banjo bolt to specification.
Torque to 15 ft.lbs.
(21 Nm)
Banjo Bolt
Sealing Washers
Handlebar Master Cyl. Clamp Bolt
Torque 25 in. lbs. (3 Nm)
Brake Line Banjo Bolt Torque
15 ft. lbs. (21 Nm)
Torque Bolt First
Brake Line