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BRAKES
Output Shaft Caliper Service (Auxiliary Brake)
Installation
1 . Reinstall caliper assembly onto brake
disc.
2.
Install upper and lower caliper bolts,
lock washers, and flat washers (G) to
caliper shield (H) and secure caliper
assembly to its mounting.
3.
Torque
caliper
mount
bolts
to
specification.
4.
Install pedal rod on brake arm with
existing washer and a new cotter key.
5.
Adjust foot pedal at 1/2" to
3/4/1
(12.7-
19.05 mm) travel of the pedal by turning
adjuster screw clockwise.
6.
(4 x 4 Models) Reinstall the middle
chain guard (D) with rear most bolt,
lock washer, flat washer (A) and spacer
(B). Bolt the forward end of chain guard
to
the
mounting
brackets
with
hardware (C).
7.
Reinstall right front and rear mud flap bolt in
footrest.
8.
Refill master cylinder with DOT 3 brake fluid and
reinstall cover and diaphragm.
9.
Refer to brake bleeding instructions in this chapter
and bleed system.
10. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when
lever/pedal is released. If the brake drags, re-check
assembly, installation and adjustment.
11. Machine should be stopped at least ten (10) times
from at least 30 miles per hour using the auxiliary
brake pedal only.
Polaris Industries Inc.
9.27
7/96
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Troubleshooting
