Output Shaft Caliper Reassembly - Polaris Magnum 2x4 Service Manual

BRAKES
Output Shaft Caliper Service (Auxiliary Brake)
Reassembly
NOTE: Clean and inspect all components before reas-
sembling.
1. Lubricate new O-rings (A) with brake fluid and
install into caliper pin bore.
2. Lubricate new seals (B) with brake fluid and install
into caliper.
3. If piston pin or axillary brake arm were removed,
lubricate all sliding surfaces of stationary and
moveable brake ramps with a thin coat of Polaris
high temp grease.
4. Align mark of stationary and moveable cam so long
side of lobe is in the up position and just to the right
of mark on stationary. Alignment marks must be
matched and cam positioned correctly, as there
are six possible combinations.
5. Reassemble adjuster screw through arm and
moveable cam. Install washer on screw inside of
cam. Reinstall lock nut and tighten until seated,
then turn an additional 112 turn tighter.
6. Using a new gasket, assemble ramp to brake
caliper. NOTE: Align marks of stationary and
caliper made in step 1. Torque bolts to 5-6 ft. Ibs.
7. Hold caliper so that the brake line fitting hole can be
covered with your finger. Close bleeder fitting and
add approximately 114 ounce of brake fluid to
piston bore. CAUTION: Brake fluid will cause
damage to painted surfaces. Wipe up any spills at
once.
8. Lubricate piston with brake fluid and install in
caliper piston bore, flat beveled end first.
Suggested area
to make align-
ment marks
Long Side
of Moveable
Ramp Lobe
Stationary
Ramp
9. Compress piston until seated in caliper and wipe off excess brake fluid from piston area.
10. Attach brake line to caliper assembly and tighten fitting with a flare nut wrench. CAUTION: Brake fluid will
cause damage to painted surfaces. Wipe up any spills at once.
11. Reinstall spring plate, brake pads and pad pins to caliper.
12. Pump the handle 10 to 15 times to purge any fluid which may have accumulated between the seals during
assembly.
13. Thoroughly wipe the piston and caliper dry.
14. Pressurize the brake system for approximately one minute. NOTE: The parking brake may be used to hold
the pressure.
15. Check for "low pressure" leaks by lightly pumping the handle 5 to 10 times.
16. Compress piston into caliper until seated.
NOTE: The brake pads will need to be spread enough to accept the brake disc when reinstalling the caliper as-
sembly.
7/96 9.26
Polaris Industries Inc.