Tracker Off-Road 500S Service Manual page 148

2. Press the piston into the caliper housing using hand
pressure only. Completely seat the piston and dust
seal; then wipe off any excessive brake fluid.
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3. Apply high-temperature silicone grease to the inside
of the caliper holder bores, O-rings, and boots.
4. Install the caliper onto the caliper holder making sure
the caliper and holder are correctly oriented.
NOTE: It is very important to apply silicone grease

to the O-rings, boots, and caliper bores prior to
assembly.
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5. Making sure brake fluid does not contact the brake
pads, compress the caliper holder toward the caliper
and 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 failure.
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146
6. Secure the brake pads to the caliper with the brake
pad pins. Apply blue Loctite to the threads of the
pins; then tighten to 13 ft-lb (17.7 N-m).
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7. Place the brake caliper assembly into position and
secure with new "patch-lock" cap screws. Tighten
the caliper to 25 ft-lb (34 N-m).
8. Place a new crush washer on each side of the brake
hose fitting and install it on the caliper. Tighten to 25
ft-lb (34 N-m).
9. 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.
10. 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 45 ft-lb (61.2 N-m) (steel
wheel), 60 ft-lb (81.6 N-m) (aluminum wheel w/black
nuts), or 80 ft-lb (108.8 N-m) (aluminum wheel w/
chrome nuts).
11. 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 cali-
per bleeder valves and direct the other end into a
container. Remove the reservoir cover; then open the
bleeder valve. Allow the brake fluid to drain until the
reservoir is empty.