Tracker Off-Road 800SX Service Manual page 176

MOD364A
3. Making sure brake fluid does not contact the brake
pads, install the inner brake pad; then install the
outer pad.
CAUTION
If brake pads become contaminated with brake fluid,
they must be thoroughly cleaned with brake cleaning
solvent or replaced with new pads. Failure to do so will
result in reduced braking and premature brake pad fail-
ure.
MOD302
4. Place the brake caliper assembly into position and
secure with new "patch-lock" cap screws. Tighten
the caliper to 45 ft-lb (61.2 N-m).
NOTE: The Torx head plug must be installed in the

caliper.
MOD512
5. Place a new crush washer on the brake hose fitting
and install it on the caliper. Tighten to 20 ft-lb
(27.2 N-m).
174
6. Fill the reservoir; then bleed the brake system (see
Periodic Maintenance/Tune-Up — Hydraulic Brake
System).
! WARNING
Never use brake fluid from an open container or reuse
brake fluid. Moisture-contaminated brake fluid could
cause vapor build-up (expansion) during hard braking
resulting in greatly increased stopping distance or loss
of control leading to injury or death.
7. Install the wheels and using a crisscross pattern,
tighten the wheel nuts in 20 ft-lb (27.2 N-m) incre-
ments to a final torque of 100 ft-lb (136 N-m).
8. Remove the vehicle from the support stand and ver-
ify brake operation.
MASTER CYLINDER ASSEMBLY
NOTE: The master cylinder is only serviceable as

an assembly.
Removing
1. Slide a piece of flexible tubing over one of the wheel
bleeder valves and direct the other end into a con-
tainer. Remove the reservoir cover; then open the
bleeder valve. Allow the brake fluid to drain until the
reservoir is empty.
MOD300
2. Remove the lower dashboard; then remove the banjo
bolt (A) and brake switch (B) securing the banjo-fit-
tings to the master cylinder; then remove the master
brake cylinder reservoir clamp and hose (C).
MOD340
3. Remove the cotter pin and pivot pin from the yoke;
then remove two cap screws securing the master cyl-
inder assembly to the frame.