Tracker Off-Road 500S Service Manual page 149

PK278A
2. Remove the front left splash panel; then remove the
two banjo bolts securing the brake switch and banjo-
fittings to the master cylinder.
PK279A
3. Remove the lock pin (A) from the brake rod pin (B).
Remove the brake rod pin from the yoke; then
remove two cap screws securing the master cylinder
assembly to the frame.
PK280A
PK281A
4. Remove the master cylinder. Discard the three crush
washers as new ones are required for assembly.
CAUTION
Brake fluid is highly corrosive. Do not spill brake fluid
on any surface of the vehicle.
Inspecting
1. Inspect the master cylinder push rod and clevis for
wear, bending, or elongation of clevis holes.
2. Inspect the push rod boot for tears or deterioration.
3. Inspect the reservoir for cracks and leakage.
4. Inspect the brake hose for cracks and deterioration
and the condition of the banjo-fittings.
Installing
1. Secure the master cylinder assembly to the frame with
two cap screws. Tighten to 15.6 ft-lb (21.2 N-m).
2. Using new crush washers, secure the banjo-fittings
to the master cylinder with new banjo bolts and the
existing brake switch. Tighten to 25 ft-lb (34 N-m).
3. Install the brake rod pin and secure with a lock pin.
4. Fill the master cylinder and bleed the brake system
(see Hydraulic Brake System in the Periodic Mainte-
nance/Tune-Up section).
147