Service Manual

11.8
BRAKES
HAND BRAKE MASTER CYLINDER
Removal
1. Clean master cylinder and reservoir assembly. Make sure
you have a clean work area to disassemble brake
components.
2. Place a shop towel or suitable catch container under the
master cylinder brake line connection. Remove the banjo
bolt fitting that connects the brake line to the master
cylinder. Discard the sealing washers.
3. Remove the Torx screws from the master cylinder clamp.
4. Hold master cylinder upright and lift the master cylinder
from the handlebars. Cover brake line orifice to avoid
spilling fluid.
Disassembly
The hand master cylinder is a serviceable component. Polaris
offers a number of service kits to rebuild this style of master
cylinder. Refer to the Polaris Electronic Parts Catalog.
Installation
NOTE: Use only OEM parts that were designed for
the model ATV being serviced. There are different
hand master cylinders for the different Polaris ATV
models. Refer to the Electronic Parts Catalog.
NOTE: Some master cylinders are not serviceable
and are replaced only as an assembly.
1. Install master cylinder on handlebars. Torque bolt furthest
from the reservoir first, followed by the bolt closest to the
reservoir. Torque clamp bolts to 70 in. lbs. (8 Nm).
NOTE: Speed up brake bleeding by purging air
before brake line is attached. Fill with DOT 4 Brake
Fluid and pump lever slowly 2 to 3 times with finger
over the outlet end to purge master cylinder of air.
2. Place new sealing washers on each side of banjo line and
torque banjo bolt to specification.
3. Fill reservoir with DOT 4 brake fluid (PN 2872189).
4. Follow brake bleeding procedures. Check all connections
for leaks and repair if necessary.
Brake Switch Replacement
1. Set the parking brake lock and locate the brake switch
behind the hand brake lever.
2. Using a small screwdriver or similar tool, push up on the
mounting tabs through the holes on the bottom side while
rotating the switch to disengage the tabs from the holes.
3. Install the new switch. The tabs should snap in place.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in
contact with finished surfaces.
Remove
Banjo Fitting
Master
Cylinder
= T
Brake Line Banjo Bolt:
15 ft. lbs. (20 Nm)
70 in. lbs.
(8 Nm)
7 in. lbs.
(0.8 Nm)
Torque Bolt First
Brake
Switch
Master
Cylinder