Polaris EV206PH-B Technical And Service Manual page 10

4. pull the cable housing, and slide the cable inner wire (C, Figure 3-1) through the slots in the brake lever,
adjuster barrel (b, Figure 3-1) and locknut (a, Figure 3-1). Seat the cable housing ferrule into the adjuster
barrel.
5. Install a handlebar grip onto the handlebar end.
6. Slide the brake lever so its bracket seats against the throttle or shifter. rotate the brake lever to the
position noted during removal, and torque the brake lever clamp bolt to the specification in table 5.
BrAkE CABLE INNEr WIrE
removal
the cable inner wire can be replaced without removing the cable housing.
1. Clip the cable ferrule from the brake cable inner wire.
2. turn out the anchor bolt (a, Figure 3-3), and release the inner wire from the pinch mechanism.
4. pull the cable housing and inner wire from the caliper barrel adjuster.
5. at the brake lever, loosen the adjuster locknut (a, Figure 3-1) and turn the adjuster barrel (b) from the
brake lever.
6. turn the barrel adjuster and the locknut (a, Figure 3-1) until their slots align with the slot in the brake lever
housing.
7. pull the cable housing from the adjuster barrel, and slide the inner wire (C, Figure 3-1) from the slots in
the housing, adjuster barrel and locknut.
8. press the brake lever toward the handlebar, and disconnect the inner wire end (C, Figure 3-1) from the
anchor (b) on the brake lever.
9. pull the inner wire from the cable housing until the far end emerges from the cable housing (a, Figure 3-2).
Installation
a fourth-hand tool (park took bt-2) is needed for this procedure.
1. apply oil to the inside of the cable housing.
2. Insert the inner wire through the brake lever end of the cable housing until the wire emerges from the
caliper end of the housing.
3. press the brake lever toward the handlebar, and connect the inner wire end (b, Figure 3-2) to the anchor
(a, Figure 3-2) on the brake lever.
14
Servicemanual_101212.indd 14-15
FIGUrE 3-2
A
B
B
A
4. pull the cable housing, and slide the cable inner wire (C, Figure 3-1) through the slots in the brake lever,
adjuster barrel (b, Figure 3-1) and locknut (a, Figure 3-1). Seat the cable housing ferrule into the adjuster
barrel.
5. at the caliper, turn the barrel adjust all the way into the caliper.
6. feed the inner wire through the caliper barrel adjuster, and seat the cable housing in the adjuster.
7. route the inner cable through the pinch mechanism on the caliper.
8. Use the fourth-hand tool to remove the slack from the cable, and torque the brake caliper anchor bolt (a,
Figure 3-3) to the specification in table 5.
9. loosen the CpS bolts with 5mm hex wrench(b, Figure 3-3) so the caliper can move freely.
10. turn the inboard pad adjuster (C, Figure 3-3) clockwise (inward toward the caliper) until the brake disc
(a, Figure 3-4) is centered within the caliper body (b, Figure 3-3). the caliper is properly adjusted if the
space on each side of the brake disc is the same.
11. pull in and hold the brake lever. Check that the rotor is still centered within the caliper body.
12. pull in and hold the brake lever. torque the CpS bolts (b, Figure 3-3) to the specification in table 5 while
holding the brake lever in.
13. release the brake lever, and spin the wheel. listen for the sound of the inboard pad rubbing against the
brake disc.
14. If rubbing is noted, turn the inboard pad adjuster counterclockwise (out from the caliper) two or three
clicks, and recheck.
15. repeat Steps 13 and 14 as needed.
16. trim the inner wire end so its end extends no more than 20 mm (3/4 in.) beyond the anchor. Crimp a new
cable ferrule onto the cable end.
17. Use the barrel adjuster (b, Figure 3-1) at the brake lever to remove any cable slack. turn the adjuster
outward until brake lever freeplay is eliminated. however, do not go so far that the caliper torque arm is
moved. make sure the caliper torque arm is completely released, and tighten the adjuster locknut (a)
against the brake lever housing.
FIGUrE 3-3
C
15
10/12/2012 12:25:50 am