haas vmc maintenance manual
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haas vmc maintenance manualIf you continue browsing the site, you agree to the use of cookies on this website. See our User Agreement and Privacy Policy.If you continue browsing the site, you agree to the use of cookies on this website. See our Privacy Policy and User Agreement for details.You can change your ad preferences anytime. This Service Manual haseasy-to-read text sections with top quality diagrams and instructions.Trust 2009 Polaris Sportsman XP 850 Service Repair Manual willgive you everything you need to do the job. Save time and money bydoing it yourself, with the confidence only a 2009 Polaris SportsmanXP 850 Service Repair Manual can provide.Models Covers:2009 Polaris Sportsman XP 8502009 Polaris Sportsman XP 850 International2009 Polaris Sportsman XP EPS 8502009 Polaris Sportsman XP EPS 850 InternationalService Repair Manual Covers: Allpages are printable. Now customize the name of a clipboard to store your clips. The VIN can be found stamped on the lower frame rail on the front LH side of the ATV (see Figure 1-1). Some of the tools listed or depicted are mandatory, while other tools maybe substituted with a similar tool, if available. Polaris recommends the use of Polaris Special Tools when servicing any Polaris product. There are exceptions in the steering, suspension, and engine areas. Always consult the exploded views or each manual section for torque values of fasteners before using standard torque. Center Distance: Distance between center of crankshaft and center of driven clutch shaft. CI: Cubic inches. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts. WARNING Improperly performing the procedures marked could result in component failure and lead to serious injury or death. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. E Emission Control System Service (California) Have an authorized Polaris dealer perform these services. Rear Bearing Carrier submerging the ATV.
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The fuel pump is non-serviceable. If the internal fuel pump Slide the boot back far enough to expose the inline cable filters require service, the fuel pump and fuel tank must be adjuster sleeve and loosen the adjuster locknut. However, in filter with hot soapy water.Oil may need to be changed more frequently if Polaris engine oil is not used. Position the ATV on a level surface. Place the transmission in park. Stop the engine and check for leaks.Re-check the oil level on the dipstick and add oil as or scratches.Disconnect the shift linkage from the shift lever. Remove the (2) screws retaining the lower portion of the air box. Remove the hose from the breaker valve located on top of the valve cover. Repeat steps 16-18. lash is correct. 22. Clean sealing surfaces of the cylinder head and valve cover. 17. Set the intake and exhaust valve lash to specification. 23. Place the transmission in WARNING park and block the wheels. Transmission Lubrication The plastic skid plate can be removed for better access to the drain plug. NOTE: It is important to follow the transmission maintenance intervals described in the Periodic Remove the fill plug (refer to “Transmission Fluid Level Maintenance Chart. Access the drain plug through the access hole in the maintenance intervals described in the Periodic front skid plate. NOTE: It is important to follow the front gearcase maintenance intervals described in the Periodic Maintenance Chart. Regular fluid level inspections should be performed as well. Access the drain plug from the rear right-hand Maintenance Chart. NOTE: If operating the ATV through water, be sure to check the PVT system components for water Remove the lower left-hand frame support. Tapered Nut Install the wheel hub, washers, and hub nut, if previously Aluminum Wheels 75 ft. lbs. (102 Nm) (Long) removed. If Front Rear cleaning is necessary, remove the corrosion with a stiff wire 7 psi (48 kPa) 5 psi (34.5 kPa) brush. Be sure they are placed between the battery terminal and cable(s). Remove the seat to access the battery.Only a qualified technician should replace worn or damaged steering parts. Use only genuine Polaris replacement parts. Position the stands so the string is To check for play in the tie rod end, grasp the steering tie rod, flush or parallel with the side of the rear tire. This will tell you which tie rod needs adjusting. Compress and release the suspension. Damping should be smooth throughout the range of travel. NOTE: Be sure handlebars are straight ahead before determining which tie rod(s) need adjustment. CAUTION Fluid Level “Eye” DO NOT OVERFILL. Excess brake fluid may cause brake drag. Frequently check the brake fluid level for the auxiliary brake system by viewing the level in the master cylinder reservoir located underneath the front rack assembly (see Figure 2-31).Polaris dealers can also order the following separately: SmartLink Module PU-47468, Vehicle Interface Cable PU-47469 and PC Interface Cable PU- 47470. This kit is available to Polaris dealers through our tool supplier, SPX (1-800-328-6657).Electronic Control Unit (ECU) - Attached to the air box, located behind the LH side panel. Fuel Injectors - Located in the Integrated Air Fuel Manifold (IAFM). Throttle Position Sensor (TPS) - Located behind the right-hand side panel. - Located on the MAG end (front) of the throttle body. Fuel Pump - Located in the fuel tank as an assembly. 11. These The Electronic Fuel Injection (EFI) system is a complete engine primary signals are compared to the programming in the ECU fuel and ignition management design. With the ignition turned off, disconnect the wire harness from the ECU by pulling the black slider out away from the An electric fuel pump assembly is used to transfer fuel to the EFI ECU while pulling down on the connector.https://ayurvedia.ch/dtv2798-service-manual If the fuel gauge reading on the instrument cluster is not working, or if the display reading differs in large comparison to the fuel in the tank, perform a resistance test on the fuel sender.Vent Fitting WARNING Always wear safety goggles when working with. Operation Overview CPS Connector The engine speed sensor is essential to engine operation, constantly monitoring the rotational speed (RPM) and position of the crankshaft. Remove the seat and upper right-hand side panel (see Chapter 9 “Seat and Side Panels”). Disconnect the shift linkage from the shift lever. Remove the spark plug wires. If Operation Overview it is faulty, it must be replaced. It can be tested using the following method: The throttle position sensor (TPS) is used to indicate throttle plate angle to the ECU. Refer to the instructions Chapter 9 “Seat and Side Panels”). If the sensor did not function correctly, replace it.Refer to Chapter 4 for additional ECT information.Operation Overview Disconnect the ECT sensor from engine harness. Remove The ignition coil is used to provide high voltage to fire the spark the T-MAP sensor to allow access to the ECT sensor. plugs. The high tension lead (coil wire) must be replaced as an assembly. Remove the seat and upper right-hand side panel to access the ignition coil (see Chapter 9 “Seat and Side Panels”). Press and hold the “MODE” button to cycle through all Use the following procedure to display diagnostic trouble codes currently active trouble codes.Washing the vehicle with a high-pressure With the engine still idling, top off the radiator with Polaris washer could damage the radiator fins and Premium Antifreeze. If no air bubbles are seen at the impair the radiators effectiveness. Then lift up on the bottle and remove it from the radiator fan shroud. Water Pump Impeller Removal NOTE: The water pump impeller, mechanical seal, drive coupler, pump shaft, and pump shaft bearing can be serviced without removing the engine. Remove the fuel tank (see Chapter 3). Do not attempt to press water pump shaft out of stator Disconnect the stator and CPS wire harnesses. Protect water pump cover gasket surface and turn cover over. Drive mechanical seal out from stator side of cover.CAUTION Refer to the following pages for water pump assembly and torque information. Be sure bearing is fully seated in cover after Stator Cover Installation Step 2, or severe crankshaft damage will result. Install new coupler hub (A) from kit onto shaft. Rod stamp can face front or rear of engine (Rod has no offset) 120 mm. M6 x 20 (10 Nm) 89 lb-in. (10 Nm) 35 lb-in. (4 Nm) Sealant bead should face the cover. Some of the engines produced have NiCaSil plated cylinder walls, while others have iron lined cylinder walls. Disconnect the ECU from the main harness. Pull down on the (2) nuts from each exhaust flange at the engine.Use the Roll Pin Removal Tool (PN 2872608), to drive out remove the plate from the vehicle.Pull the shaft back towards the transmission to remove it from the front 17. Remove the (2) screws retaining the IAC mount plate to the engine isolator mount to the engine and remove the lower frame at the front of the engine.Use only Polaris PS-4 Plus 2W-50 Synthetic engine oil. Never substitute or mix oil brands. Serious engine damage can result. Remove (2) breather housing bolts (A). Compare to Mark or tag rocker arms and shafts to keep them in their specifications (See “Engine Specifications - EH085OLE- respective locations for assembly. If warp exceeds the service limit, replace the Wear eye protection when removing and installing cylinder head. Compare to specifications. brush. Check valve face for runout, pitting, and burnt spots. To Measure valve stem in several places. Note difference between intake and Clean all accumulated carbon deposits from combustion exhaust guide height below.Intake Valve Guide Height: 8.93 - 9.43 mm NOTE: Carbon Clean Fuel Treatment (2871326) can be used to help remove carbon deposits. Rinse contact point on the valve will be very narrow, and is and dry with compressed air.Prepare cylinder head gasket sealing surfaces by cleaning Set cylinder head in place on alignment pins. Apply engine thoroughly to remove all residue. The head gasket must be oil to threads and flange of the (6) main cylinder head bolts. Turn adjuster screws out (counterclockwise) until they lightly seat against rocker arm. NOTE: DO NOT force screws against rocker arm. Also refer to Camshaft Timing Quick Reference (page 5.39). Slide sprocket onto camshaft, aligning slot in sprocket with pin. Rotate camshaft clockwise until pin (A) is facing UP (use a wrench across the flats on the sprocket end). Lubricate tensioner plunger and install in tensioner bore with check valve end of plunger (B) facing OUT (toward cap plate). Rotate plate and gasket into position and start the inner bolt. Slowly draw bolts evenly until snug. CAUTION The rotor contains powerful magnets. Use caution when removing and installing the stator cover.These screws secure Hold puller body (A) and tighten center bolt (B) to remove the pump. Replace if feeler gauge through the pump outlet window and compare debris has entered, or if oil pressure was outside of specified to specification. range. Some pistons may have an orientation marking. Note the arrow (A) should face the MAG end of crankshaft. NOTE: Replacement pistons can be installed in either orientation as they are symmetric. Remove pin and replace Lay gear assembly on press plate with split gear side UP.Press shaft into gear assembly until seated against washer. Replace crankshaft if any journal is scratched or pitted. Measure each main journal (A) and rod journal (B) in two locations, 90 degrees apart. Record measurements. Difference between measurements is Secure connecting rod lightly in a soft jawed vise.Note location of the piston circlip gap (A) at top.Use the piston to push the Lay a straight edge across cylinders (upper crankcase).Rotate ring to place end gap generally toward (intake) side Crankcase Preparation - Upper of piston as shown below. Refer to Oil Flow Diagram (page 5.4) and trace the oil Install top ring with “0”. Be sure ring end gaps are positioned at least 120 degrees CAUTION apart. Install new bolts and tighten evenly until snug. 12. Torque bolts using the following procedure: Refer to illustration Crankcase Assembly (Upper) page 5.54. Install New Clean the bearing bore surfaces of upper crankcase (main bearings), connecting rods, and connecting rod caps. Match marks Align tab of a new main bearing with the slot in main bearing bore of crankcase. See “Balance Shaft Timing” on page 5.56. Align single dot of drive gear between two dots of balance Balance shafts are identical but should be installed in the gear. Refer to Oil Flow Diagram (page 5.4) and trace the oil path from the through the lower crankcase. Flush all passages with solvent and then warm soapy water. Rinse with clear warm water and dry with compressed air. Be sure passages are clean and dry before assembling the lower crankcase. ITEM TORQUE VALUE Inspect the linkage rod pivot end attached to the 10-14 ft. lbs. transmission bellcrank and the snap linkage attached to the Transmission Fill Plug (14-19 Nm) gear selector. Transmission Removal Position the vehicle on a level surface. Remove the seat and side panels (see Chapter 9). Disconnect the negative (-) battery cable (see Chapter 2). Once you have cleared the coupler, carefully lift the and remove the support from the vehicle.Use a soft-faced hammer to hold the coupler.Coupler Output Shaft Thread bolts in pin holes. Lift up on each end of the shift fork and rotate the fork out the compensator assembly.Compensator Assembly Rear Output Shaft 12. Washer Snap Ring Detent Plug 20. Remove the retaining ring and washer from the cam shift shaft. Shaft bearings can be serviced using an arbor press. Input Shaft Reverse Shaft Primary Shaft. The “UP” stamping on each washer should face out when assembling the washer stack. “UP” Marking Belleville Washers. If the bellcrank shift shaft was disassembled, install the gear sector with the step facing the O-ring. Inspect all seals and O-rings for damage. If transmission was disassembled, seal and O-ring replacement is Replace recommended (see exploded view above). Install the oil deflector plate and install new retaining cam. screws. Torque screws to specification. Deflector Plate Retaining Screws: 7-10 ft. lbs. (9-14 Nm) 19. Apply RTV silicone sealant to the outside edge of the inner facing up).Remove the rubber coupler and inspect it for signs of Engine Transmission excessive wear or damage. Replace as needed. Coupler Coupler Install the rubber coupler into the engine coupler. Be sure rubber coupler is properly mounted. Install the rear propshaft and torque the retaining bolts to and torque to specification.Apply Loctite 2760 to the bolt threads. 15 ft. lbs. 10-14 ft. lbs. (20 Nm) (14-19 Nm) 17-23 ft. lbs. During the development of a Polaris ATV, the PVT system is matched first to the engine power curve; then to PVT System Fastener Torques average riding conditions and the vehicle’s intended usage. Shift free operation. Periodic inspection and maintenance is required weights should not be changed or altered without first having a to keep the system operating at peak performance. For inspection of clutch components, please contact your Polaris dealer. Shift Clutch malfunction.Some fasteners and procedures will vary. Refer to the appropriate parts manual for proper fastener placement. Loosen the clamps and remove the PVT outlet duct from the inner PVT cover. Remove the (10) screws that retain the inner PVT cover to drive clutch.Drive Clutch Holder (9314177) 11. Remove the drive clutch retaining bolt by turning the bolt in a clockwise direction. Replace the outer PVT cover seal.Torque screws to specification. Inner PVT Cover Screws: 6-8 ft. lbs. (8-11 Nm) Outer PVT Cover Screws: 45-50 in. Belt Removal 2877408 Position the vehicle on a level surface and place the transmission in Park. Elevate and safely support the rear of the vehicle. Remove the left rear wheel from the vehicle. Break in the clutches and the “Polaris” label can be read.The springs, which have a higher rate when the clutch is in neutral, will increase clutch engagement RPM.Replace clutch assembly if worn or damaged.Be sure to note the number and thickness of these washers. Turn roller with your finger. If If clearance exists, replace all buttons and inspect surface you notice resistance, galling, or flat spots, replace rollers, of towers. Inspect the contact surface of the weight. The surface should be smooth and NOTE: Remove cover, spring, and spider following free of dents or gall marks. Inspect the weight pivot bore instructions for drive clutch removal, then proceed and pivot bolts for wear or galling. Replace the drive clutch assembly if shaft bushing. Inspect both sheaves for signs of wear, grooving or is worn or damaged. In order to avoid serious burns, wear insulated gloves during the Item Qty. A, B EBS Puller Tool 5132027. Cover Bushing Removal Install main adapter (Item 8) on puller. Install nut (C) onto end of puller rod and hand tighten. Turn puller barrel to increase tension on sheave if needed. Using Removal Tool Nut (C) a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Torque with NOTE: It is important that the same number and smooth motion to avoid damage to the stationary sheave.Using Compression Extensions PN PS-45909, press down on top of the spider assembly, compressing the Clutch Disassembly spider onto the shaft. Remove snap ring (A) and slowly Remove driven clutch from the transmission input shaft. Remove the E-clips (F), washers (G), and the clutch rollers (H). Inspect the bearing for wear. Spin the bearing, if the bearing does not spin smoothly, replace it. To remove the IMPORTANT: Special Tools Required bearing, press the bearing off the shaft. EBS Clutch Bushing Tool Kit - 2201379 Item Qty. Install puller adapter (Item 10) onto puller. Install adapter reducer (Item 9). Install adapter (Item 9) onto puller. Using a hand held propane torch, apply heat around outside of bushing until tiny smoke tailings appear. Put Install a new bearing onto the output shaft using a press.Install the cam (helix) assembly over the shaft. Line up the 8700220. Using Compression Extensions PN PS-45909, “X” on the cam, “X” on spider, and “X” on the stationary press down on the top of the spider assembly, pushing the sheave or use the marks previously made before spider onto the shaft. Engine RPM below specified operating -Drive clutch shift weight too heavy. -Install correct shift weight kit to match engine range, although application.Clean, repair or replace as necessary. PVT cover on cover. Seal PVT system ducts.Item Nut Type Specification The self-locking properties of the nut or bolt Tapered Nut are reduced or destroyed during removal Aluminum Wheels 75 ft. Remove the cotter pin from the bottom of the tie rod end.Bearing Installation Visually inspect bearing for moisture, dirt, or corrosion. Thoroughly clean the front bearing carrier housing and the NOTE: Due to extremely close tolerances and outer race on the new bearing. Be sure that all oil residue minimal wear, the bearings must be inspected has been removed from each surface. Install the drive shaft axle through the backside of the bearing carrier. Install the upper and lower ball joint ends into the bearing carrier. Install the pinch bolts and torque to specification. Front Caliper Mounting Bolts: 37 ft. Tighten nut slightly if necessary to align Removal cotter pin holes. Elevate front of vehicle and safely support machine under 80 ft. lbs. the frame area. Install a new spring ring on the end of the drive shaft and Using a soft faced hammer, lightly tap on the upper A-arm apply an anti-seize compound to the splines.CAUTION Use the Roll Pin Removal Tool (PN 2872608), to drive out the roll pin from the front propshaft. Continually check for free movement of bearing cross as bearing caps are assembled. Force U-joint cross to one side and lift out of inner yoke. Once the AWD is enabled, it remains enabled until the switch is turned off. Engaging the Front Gearcase: Active Descent Control (ADC) Operation is controlled by the ECU grounding and ungrounding is controlled by the ECU and will not enable until the following the coil. The resistance value should be within specification. Check for Wear Bands Check to make sure the AWD coil is seated in the U-shaped insert that is pressed into the gearcase cover. Stop engine and place gear selector in Park. CAUTION Cotter Pin Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Drain and properly dispose of used lubricant. Remove any metal particles from the drain plug magnet. Remove the (4) screws retaining the piston pump assembly to the gearcase and remove the pump. Inspect the thrust Remove the armature plate. Inspect the armature plate for bearing (A) for wear.Replace as required. NOTE: Thrust bearing (A) located between the two output assemblies is pressed into the clutch pack Remove the ring gear and roll cage from the gearcase as an and is not removable. Inspect the roll cage (C) for damage or cracks. The rollers Uneven wear of the armature plate indicates a warped plate, must slide up and down freely within the roll cage surfaces. Thoroughly clean all gearcase components before beginning reassembly. Lightly crimp the thrust pad to hold the pad on the cover and holes during installation.Verify the armature plate tabs align with tab recesses in the roll cage. NOTE: Ring gear backlash is set at the factory. No adjustment is required, unless the front cover is Set the gearcase upright. Add the recommended amount of fluid through the fill hole.Maintain the fluid level even with the bottom threads of the fill plug hole. Position the vehicle on a level surface and allow the vehicle to sit for at least 30 minutes. 10. Repeat steps 7-9 on the remaining bleeder valve. Thoroughly clean the areas around the ADC reservoir and 11. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. While rotating bearings by outer race on the new bearing. Be sure that all oil residue hand, inspect for rough spots, discoloration, or has been removed from each surface. If replacement is required, slide shafts out and remove the bushings with a drift punch. Torque wheel nuts to specification.Removal Elevate rear of vehicle and safely support machine under the frame area. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. Install a new spring ring on the end of the drive shaft and apply an anti-seize compound to the splines. Inspect the axle splines and CV boots for any damage. Fill the cavity behind the balls and the splined hole in the joint’s inner race. Pack the ball CAUTION tracks and outer face flush with grease. Using a side cutters, cut away and discard the boot clamps. Axle Boot Clamp Tool Remove the large end of the boot from the plunging joint PU-48951 and slide the boot down the shaft. Pull on the joint to test that the circlip is seated and that the joint is securely fastened to the shaft. FRONT SHAFT 18. Remove excess grease from the plunging joint’s external surfaces and place the excess grease in the boot. Spring Ring 19. Propshaft NOTE: If needed, remove the right rear wheel to gain better access to the rear propshaft bolts. Remove the (4) bolts retaining the rear propshaft to the rear gearcase input shaft coupler. Gearcase Removal Position the vehicle on a level surface and remove the seat. Drain the rear gearcase lubricant (see Chapter 2). Remove the rear cab (see Chapter 9). Remove the through-bolt fastener retaining the upper A- vehicle as an assembly.Pivot the wheel hub and bearing carrier down to remove the drive shaft. IMPORTANT: Take care not to stretch the brake line while removing the drive shaft. IMPORTANT: Pinion ring gear shimming information is NOT provided. The components are matched at the factory which requires special OEM tooling in order to properly assemble and shim the gears. If the gearcase is completely assembled, perform the “Gearcase Disassembly and Inspection” procedure. Support the pinion shaft and press the bearing off the shaft (see Figure 8-27). Seal depth should be Grease all seals with Polaris All Season Grease (PN approximately.110 in. (2.79 mm) from the main surface. 2871322) upon assembly to prevent from damaging seals. Torque to specification and 15. Add Polaris ATV Angle Drive Fluid to rear gearcase (see install a new cotter pin. Chapter 2). Torque drain and fill plugs to specification. Using the “Multi-Function Pliers” eases removal and prevents from damaging the push rivets and body Lower LH Frame Support 30 ft. Pull upward abruptly to disengage the under-seat fasteners. Reverse this procedure to reinstall components. Remove the seat and upper side panel (see “SEAT AND SIDE PANELS”). Remove the push rivets and screws that retain the footwell. Remove the (4) bolts retaining the upper front bumper to the frame. Using a clean shop rag or towel, cover the fuel fill hose inlet to prevent dirt or debris from entering the fuel tank. Removal Remove the seat and upper side panels (see “SEAT AND SIDE PANELS”). Remove the (8) Torx-headed fasteners as shown below. Aluminum Wheels 75 ft. lbs. (102 Nm) IMPORTANT: Take note of all vent line, wire harness Steel Wheels 45 ft. The pin should line up with the alignment hole in the lower block and should face the front. Remove the front rack and front cover (see Chapter 9). Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9). Reverse the “Steering Post Removal” procedure to reinstall the steering post. Refer to the “Steering Exploded View” for torque values. Remove NOTE: Make sure to route all vent lines, wire harness and throttle cable correctly into the lower. Upper Steering Post Removal Remove the front rack and front cover (see Chapter 9). Remove the upper and lower headlight pods from the handlebar bracket (see Chapter 9). Carefully lift the power steering unit up to disengage the the fuel tank. Cover the tank inlet and remove the fuel tank lower steering coupler and remove it from the chassis.Install the fuel tank assembly, fuel line and reconnect the specification. Refer to “Steering Exploded View (EPS fuel pump harness (see Chapter 3). Models)”. 12. Reinstall the upper steering post bushing bracket and torque Reconnect the (2) electrical harnesses to the power steering the (2) fasteners to specification. Use the following procedure to replace the tie rod assembly or Install the new tie rod assembly (C). DO NOT reuse old Elevate and safely support the front of the vehicle and hardware. Removal Correct Driver Placement IMPORTANT: Do not reuse a ball joint if it has been removed for any reason. If removed, it must be replaced. Press into the A-arm in this direction Place driver HERE to support A-arm Upper A-arm Shown After the new ball joint is installed into the A-arm, install a new retaining ring.Remove the fastener retaining the stabilizer linkage to the lower A-arm. The following procedure details upper and lower A-arm removal and replacement on one side of the vehicle. Elevate and safely support the rear of the vehicle and remove the rear wheel. CAUTION Serious injury may result if machine tips or falls. Be sure machine is secure before beginning this service procedure. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life. Do not fill the reservoir beyond the MAX LEVEL line. When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Bleeding Procedure Front Brake System Bleeding CAUTION Remove the reservoir cover from the hand brake master cylinder and verify fluid is at specified level. Using a funnel, add brake fluid to the MAX level mark on the reservoir. 10. Add DOT 4 brake fluid to.25” -.30” (6 - 8 mm) from the top of the reservoir. Polaris Switch Cylinder offers a number of service kits to rebuild this style of master cylinder. Refer to the Polaris Electronic Parts Catalog. Replace components as needed. Operation Overview Reverse this procedure when reinstalling and torque mounting fasteners to specification. When the brake pedal is applied it contacts the piston of the foot brake master cylinder. Remove Caliper Push mounting bracket inward and slip the outer brake pad past the edge of the pin. Caliper Removal CAUTION Loosen the (4) wheel nuts. Elevate and support the side of the ATV in which the caliper New bolts have a pre-applied locking agent is being serviced. Inspect caliper body for nicks, scratches or wear. Measure bore size and compare to specifications. Replace if damage is evident or if worn beyond service limit. Using a hammer and a small punch, remove the piston from the caliper body, then remove the square O-rings (see “BRAKE CALIPER - Exploded View”). All Season Grease (PN 2871423), and install the rubber Install the wheel and (4) wheel nuts. Torque wheel nuts to dust seal boots. Replace the disc if any deep gouges are evident. Replace disc if worn beyond service limit. Use the castle nut.