Master Cylinder Installation; Brake Bleeding / Fluid Change - Polaris RZR XP 1000 2014 Service Manual

BRAKE SYSTEM

MASTER CYLINDER INSTALLATION

1. Install the two mounting fasteners retaining the
master cylinder to the frame. Torque fasteners to
specification.
2. Install the brake lines as they were removed. Use
new sealing washers for the banjo fittings. Torque
fasteners to specification.
TORQUE
Banjo Bolts:
15 ft-lb (20 Nm)
Master Cylinder Mounting Fasteners:
23 ft-lbs (31 Nm)
3. Install the clip retaining the clevis pin between the
master cylinder to the brake pedal lever.
4. Fill the master cylinder with DOT 4 brake fluid.
5. Perform the BRAKE BLEEDING / FLUID CHANGE,
page 9.8.
6. After installing the foot brake check pedal free-play.
Pedal free-play should not exceed .090" (2.286 mm).
9.8

BRAKE BLEEDING / FLUID CHANGE

When bleeding the brakes or replacing the fluid always
start with the furthest caliper from the master cylinder.
This procedure should be used to change fluid or bleed
brakes during regular maintenance.
CAUTION
Always wear safety glasses when handling chemicals
and fluids.
CAUTION
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
1. Clean master cylinder reservoir cover thoroughly and
w
remove the cover .
2. If changing fluid, remove old fluid from reservoir
with a Mity Vac™ pump or similar tool.
Mity Vac™:
2870975
3. Add brake fluid to the indicated MAX level of
reservoir.
Polaris DOT 4 Brake Fluid
2872189
4. Begin bleeding procedure with the caliper that is
farthest from the master cylinder. Install a box end
wrench on caliper bleeder screw. Attach a clean,
clear hose to fitting and place the other end in a
clean container. Be sure the hose fits tightly on
fitting.
5. Have an assistant slowly pump foot pedal until
pressure builds and holds.
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
NOTE
© Copyright Polaris Industries Inc.
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