Master Cylinder; Removal; Installation; Brake Pedal Lever - Polaris 2008 RZR Service Manual

MASTER CYLINDER

Removal

1. Locate the master cylinder above the LH front tire in the
wheel well area.
Master Cylinder
2. Remove the clip (A) from the clevis pin (B) that attaches
the master cylinder to the brake pedal lever.
A
D
3. Place a container to catch brake fluid under the master
cylinder brake line banjo bolts (C).
17 ft. lbs.
D
(23 Nm)
B
C
15 ft. lbs.
(20 Nm)
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
NOTE: Make note of front and rear brake line
locations to master cylinder.
4. Loosen the brake line banjo bolts (C) and allow fluid to
drain.
NOTE: Dispose of fluid properly. Do not re-use.
5. Remove the two mounting fasteners (D) that secure the
master cylinder to the frame.

Installation

1. Reverse Steps 1-5 for master cylinder installation.
Refer to the torque specifications in the illustration.
2. After installing the foot brake check pedal freeplay. Pedal
freeplay should not exceed .090" (2.286 mm).

BRAKE PEDAL LEVER

Pedal Removal

1. Locate the brake pedal lever (L) and remove the master
cylinder clevis pin (B) and clip (A).
2. Remove the E-ring (E) from the pedal mount and remove
the brake pedal lever (L) from the vehicle.
L
A

Pedal Installation

1. Reverse "Removal" steps to install brake pedal lever.
Brake pedal freeplay should not exceed .090" (2.28 mm).
Brake Pedal Freeplay:
.090" (2.28 mm)
BRAKES
E
B
9
9.5