Master Cylinder; Removal; Installation - Polaris RZR 170 2009 Service Manual

MASTER CYLINDER

Removal

NOTE: The master cylinder is not serviceable but can be
replaced as an assembly.
1. Clean master cylinder reservoir cover and surrounding
area under front left cab thoroughly to prevent debris from
entering the reservoir. Remove the cover.
2. Draw as much fluid as possible from the reservoir to
minimize spillage.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
3. Place a container under the master cylinder to catch brake
fluid. Loosen hose clamps (A) and remove hoses from hose
adaptors. Drain remaining fluid from reservoir and hoses.
Immediately cover and seal ends of supply hoses to prevent
contamination.
4. Remove front and rear brake line banjo bolts (B).
Immediately cover and seal ends of brake lines to prevent
contamination.
NOTE: Note brake line locations on master cylinder.
NOTE: Dispose of fluid properly. Do not re-use.
A 15 in-lb. (1.7 Nm)
14.5 ft-lb. (19.6 Nm)
B
5. Remove clip (C) and disconnect brake actuator rod clevis
from brake pedal.
6. Remove the two mounting fasteners (D) that secure the
master cylinder to the frame.
C
D 17.5 ft-lb. (23.0 Nm)

Installation

1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the removal steps.
Install new sealing washers on brake lines.
2. After installing the master cylinder, perform the following:
• Fill the reservoir with Polaris Dot 4 Brake Fluid (PN
2872189) from a new, sealed container.
• Bleed the master cylinder and both front and rear brake
lines and calipers. See "BRAKE BLEEDING / FLUID
CHANGE" on page 6.6.
• Inspect pedal free play and pedal travel. See "Brake
Pedal Inspection / Adjustment" on page 6.8.
• Test brake system for proper function before returning
the vehicle to service.
BRAKES
6
6.21