Master Cylinder Installation - Polaris 2009 Trail Boss 330 Service Manual

MASTER CYLINDER
INSTALLATION
Notice: When replacing the brake master cylinder
assembly or master cylinder parts, use the correct
parts. There are different brake master cylinders for
the different Polaris ATV models. Refer to your parts
manual or guide for the correct parts. The master
cylinder is not serviceable and is replaced as a
unit.
1. Install master cylinder on handlebars. Torque
clamp bolts to 25 in. lbs. (3 Nm). Torque the inside
bolt first as indicated in the illustration to the right.
5 in.lbs. (0.56 Nm)
Torque both bolts to
25 in.lbs. (3 Nm)
NOTE: To speed up the brake bleeding procedure,
the master cylinder can be purged of air before brake
line is attached. Fill with DOT 4 Brake Fluid and pump
lever slowly two to three times with finger over the
outlet end to purge master cylinder of air.
Torque this bolt first
2. Place new sealing washers on each side of banjo
line and torque banjo bolt to specification.
Torque to 15 ft.lbs.
(21 Nm)
Banjo Bolt
Sealing Washers
Handlebar Master Cyl. Clamp Bolt
Torque 25 in. lbs. (3 Nm)
Brake Line Banjo Bolt Torque
15 ft. lbs. (21 Nm)
3. Fill reservoir with DOT 4 Brake Fluid.
Polaris DOT 3 Brake Fluid
(PN 2870990)
4. Follow bleeding procedures as outlined in this
chapter. Check all connections for leaks and
repair if necessary.
BRAKES
Brake Line
9.9