Caliper Replacement; Caliper Assembly; Brake Pad Replacement; Brake Disc Replacement - Polaris 340 CLASSIC 2006 Manual

CALIPER REPLACEMENT

The only serviceable item in the brake caliper is the brake
pads. If any service is required of the caliper a new caliper is
available.
1. The brake line will need to go in the same orientation as it
was when it is replaced. Note the orientation of the brake
line before removing it.
2. Remove the banjo bolt from the brake line and tie up so
that all the brake fluid does not leak out.
3. On a liquid cooled caliper, you will need to drain the
coolant from the coolant hoses.
3
1
5
Caliper
4. Remove the two bolts (1) holding the caliper (2) to the
chaincase.
5. Remove the caliper from the chaincase.

CALIPER ASSEMBLY

1. Replace caliper bolts (1) and torque them to 18-20 ft-lb
(24-27Nm).
2. On a liquid cooled caliper, hook up the coolant lines.
3. Place the brake line on the caliper in the same orientation
as it was before it was removed.
4. Clean the threads of the banjo bolt and the threads in the
caliper.
5. Install banjo bolt into the caliper and torque it to 168-216
in-lb (18.9-24.4Nm).
6. Bleed the brakes. See "BRAKE FLUID REPLACEMENT
& BLEEDING" on page 9.3.
7. On a liquid cooled caliper you will need to bleed the
cooling system of any trapped air, See "COOLING
SYSTEM BLEEDING" on page 3.8.

BRAKE PAD REPLACEMENT

Brake pads need to be replaced if the total
thickness of the pads and backing are less
than.250" (6.35mm).
1. Remove brake pad retaining pin (3).
2. Remove the brake pads (4).
3. Inspect the brake disc (5) for any wear.
4. Replace brake pads in reverse order of

removal.

BRAKE DISC REPLACEMENT

4
The brake disc should be replaced if the thickness of the disc is
below .193"(.49cm).
2
1. Remove the chaincase, see See "8.37 CHAINCASE
REMOVAL" on page 7.8..
2. Slide the brake disc from the jackshaft.
3. Check the jackshaft for any damage.
4. Replace the o-ring on the jackshaft
5. Replace the brake disk.
6. Assemble the chaincase.

WIDETRAK BRAKE CALIPER

REMOVAL
1. Remove brake cable.
2. Remove retaining bolts, making note of location of hex
head bolt (with flat washer) and recessed Allen bolt.
NOTE: Before performing next step, note position of
two spring clips.
3. Remove upper guide bushing and pads. Remove lower
guide bushing. Inspect pads and replace if worn beyond
service limit.
4. With actuating arm facing up, carefully remove tension
BRAKES
Brake Pad
.250" (6.35mm)
9.5