Front Master Cylinder Installation - Victory Cross Roads Classic Service Manual

BRAKES
18. Assemble spring to new piston assembly as shown
with small end to piston. Large diameter of beveled
edge on piston seals (L) face toward spring. Install a
new retaining ring on end of piston with machined edge
(sharpest of the two edges) facing out (M).
Brake
Apply special assembly oil
to cups (included with parts kit)
19. Carefully install spring / piston assembly into master
cylinder bore. Work the front piston seal carefully past
the chamfer and into bore. Use care not to damage or
fold the seal when working it past the chamfer.
20. Continue to install the piston until the rear seal is past
the chamfer. Push and hold the piston in far enough to
allow the retaining ring to be installed.
15.28
9924047 - 2012-2013 VICTORY Cross Roads / Cross Country Service Manual
21. Be sure retaining ring is fully seated in the groove.
22. Clean the bore from the retaining ring outward, so the
23. Install new boot, seating the outer edge fully in the bore
L
24. Apply special lubricant from kit to brake lever contact
25. Install master cylinder on handlebar. See page 15.28.

Front Master Cylinder Installation

M
Also refer to handlebar illustration on page 12.4.
1. Clean mounting surface on handlebar.
2. Loosely install master cylinder, clamp, and screws.
3. Torque rear clamp screw first then torque front screw
4. Connect brake hose to master cylinder with banjo bolt
5. Install brake light switch. Torque screws to 11 in-lbs
6. Lubricate brake lever bushing with special lubricant
7. Install mirror, adjust to proper angle, hold in position
Brake
© Copyright 2012 Polaris Sales Inc.
outer edge of the new dust boot adheres properly and
will not dislodge from the bore.
and engage outer lip of boot in piston groove.
surface.
Rotate clamp on handlebar until parting line of clamp
is aligned with parting line of right bar switch or position
so top of reservoir is level with bars in the straight
ahead position.
to 80 in-lbs (9 Nm).
and new sealing washers. Torque banjo bolt to18 ft-lbs
(24.5 Nm).
(1.2 Nm). Connect switch wires.
from kit and install lever. Torque pivot screw to 9 in-
lbs (1.0 Nm). Hold screw and torque nut to 52 in-lbs
(6 Nm).
and tighten nut securely.