Front Master Cylinder; Removal; Installation - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

BRAKES

FRONT MASTER CYLINDER

Removal

1. Clean master cylinder and reservoir assembly. Make
sure you have a clean work area to disassemble
brake components.
2. Remove master cylinder from handlebars.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in
contact with finished surfaces.
3. While holding upright, continue to remove master
cylinder. Cover the brake line to avoid spillage when
removing the brake line banjo bolt.

Installation

1. Install master cylinder on handlebars. Torque
mounting bolts to specification. Torque the inner bolt
first as indicated in the illustration below.
Master Cylinder Mount Bolt:
25 in-lbs (3 Nm)
Torque Inner Bolt First
9.12
2. Place new sealing washers on each side of banjo
fitting on the brake line and torque banjo bolt to
specification.
3. Fill reservoir with DOT-approved brake fluid.
NOTE:
procedure, the master cylinder can be purged of
air before brake line is attached. Fill with DOT-
approved brake fluid and pump lever slowly two
to three times with finger over the outlet end to
purge master cylinder of air.
4. Follow proper bleeding procedures. Check all
connections for leaks and repair if necessary.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
Banjo Bolt Torque:
15 ft-lbs (21 Nm)
To speed up the brake bleeding