CHAPTER 8 BRAKES/FINAL DRIVE

Transcription

1 CHAPTER 8 BRAKES/FINAL DRIVE Data Hydrauli Brake System Operation Type 1 Master Cylinder Overhaul Type 2 Master Cylinder Overhaul Type H1 Brake Caliper Removal and Inspetion Type H1 Brake Caliper Repair and Assembly Type H2 Brake Caliper Removal and Repair Type H2 Brake Caliper Assembly Type 3 Master Cylinder Overhaul Type H3 Brake Caliper Overhaul Type H4 Brake System Servie Type H5 Brake System Servie Bleeding Proedures for Polaris Brake Systems Type M1 Brake Overhaul and Pad Replaement Type M2 Exploded View Type M3 Exploded View. " Jakshaft Speed VS MPH Chart... " Type 1 Drive System Overhaul Type 2 Drive System Overhaul Type 3 Drive System Overhaul Type 4 Drive System Overhaul Drive Shaft Sproket Installation Tips " Series 300 Transmission Overhaul Reverse Kit Servie Tips /94

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3 Data C 1985 BRAKE DRIVE GEARS MODEL TYPE TYPE CHAIN DRIVE SPROCKET DIAMETER A DRIVE SPROCKET POSITION Referene Page 8.53 B C D E Star M1 1 Diret Drive SS M1 1 Diret Drive Trail H2 2 19/35/ H2 2 19/35/ H3 2 19/35/64 Long Trak M2 2 19/35/ BRAKE DRIVE GEARS MODEL TYPE TYPE CHAIN DRIVE SPROCKET DIAMETER A DRIVE SPROCKET POSITION Referene Page 8.53 B C D E Star M1 1 Diret Drive Sprint M1 1 Diret Sprint ES Drive SS M1 1 Diret Drive Trail H2 2 21/35/ H2 2 19/35/ LE H3 2 21/35/64 Long Trak M2 2 19/39/ o 8.1 8/94

4 Data 1987 BRAKE DRIVE MODEL TYPE TYPE GEARS CHAIN DRIVE SPROCKET POSITION DRIVE Referene Page 8.53 SPROCKET A B C D E DIAMETER Star M1 1 StarTrak M2 2 Sprint M1 1 Sprint ES Sport H2 2 Trails H H H3 2 Long Trak RLR M BRAKE DRIVE MODEL TYPE TYPE Star M1 1 StarTrak M2 2 Sprint M1 1 Sprint ES Sport H2 2 Trail H2 2 Trail SKS 400 H SKS 650 H SKS Long Trak RLR M2 4 Diret Drive 15/39/ Diret Drive 17/35/ ) 21 /35/ /35/ /35/ /39/ DRIVE SPROCKET POSITION DRIVE Referene Page 8.53 o GEARS SPROCKET A B C D E CHAIN DIAMETER Diret Drive 15/39/ Diret Drive 17/35/ /35/ /35/64 19/35/ /35/64 21/35/ /35/64 19/39/ /94 8.2

5 Data C 1989 BRAKE DRIVE GEARS MODEL TYPE TYPE CHAIN DRIVE SPROCKET DIAMETER A DRIVE SPROCKET POSITION Referene Page 8.53 B C D E Star M1 1 Diret Drive StarTrak M2 2 15/39/64 Sprint ES M1 1 Diret Drive Sport H2 2 17/35/62 Sport GT Trails H2 2 21/35/ H2 2 19/35/ H2 2 19/35/ SKS 18/35/ H3 2 21/35/ SKS 19/35/64 Long Trak M2 4 19/39/66 RLR SuperTrak M2 4 19/39/ BRAKE DRIVE GEARS MODEL TYPE TYPE CHAIN Star M1 1 Diret Drive StarTrak M2 2 15/39/64 Sprint ES M1 1 Diret Drive Sport H2 2 17/35/62 Sport GT Trails H2 2 21/35/ H2 2 19/35/ H2 2 19/35/ SKS 18/35/ H3 2 21/35/ SKS 19/35/64 SuperTrak H1 4 19/39/66 WideTrak H1 4 19/41/ DRIVE SPROCKET DIAMETER A DRIVE SPROCKET POSITION Referene Page 8.53 B C D E /94

6 Data 1991 BRAKE DRIVE MODEL TYPE TYPE Star Lite M1 1 Lite M1 1 Sport H2 2-3 Sport GT Trail H2 2-3 Trail Deluxe 440 H H SKS 650 H SKS RXL SuperTrak H1 4 WideTrak H BRAKE DRIVE MODEL TYPE TYPE Star Lite M1 1 Lite M1 1 Lite Deluxe Lite GT M2 3 Sport H2 3 Sport GT Trail H2 3 Trail Deluxe 440 H XC R H3 500SP H2 3 Classi 500 SKS 650 H3 3 RXL 650 RXL SKS SuperTrak M2 4 WideTrak M2 4 8/94 GEARS CHAIN Diret Drive Diret Drive 16/35/62 16/39/64 21/35/64 21/39/66 21/39/66 21/39/66 20/39/66 21/35/64 19/35/64 20/35/64 19/39/66 19/41/66 GEARS CHAIN Diret Drive Diret Drive 16/39/64 16/35/62 16/39/64 21/39/66 21 /39/66 21/39/66 20/39/66 21/39/66 20/35/64 20/35/64 21/39/66 19/39/66 19/41/66 DRIVE SPROCKET POSITION DRIVE Referene Page 8.53 SPROCKET A B C D E DIAMETER DRIVE SPROCKET POSITION DRIVE Referene Page 8.53 SPROCKET A B C D E DIAMETER

7 IJ I BRAKES I FINAL DRIVE Data C 1993 BRAKE DRIVE GEARS MODEL TYPE TYPE CHAIN DRIVE SPROCKET DIAMETER DRIVE SPROCKET POSITION Referene Page 8.53 A B C D E o 500 "W" Star Lite M2 2 15/41/66 Star Lite GT M2 2 15/41/66 Lite M2 2 16/39/64 Lite Deluxe M2 2 16/39/64 Lite GT M2 2 16/39/64 Sport H4 3 16/35/62 Trail H4 3 21/39/64 Trail Deluxe H4 3 16/39/ H4 3 21/39/ SKS H4 3 20/39/66 XCR H /39/66W WideTrak M2 4 19/41/66 Classi H /39/ EFI H4 3 21/39/66 EFI SKS H4 3 20/39/66 XLT H4 3 21/39/66W XLT SKS H4 3 20/39/66W XLTSP H /39/66W Classi Touring H4 3 20/39/66 RXL H5 3 20/35/64W RXLSKS H5 3 21/39/66W Storm H5 3 23/37/66W Storm SKS H5 3 23/37/66W All 1993 models, ex ept WideTrak, the drive shaft is.250" longer and sproket positions are measured to sproket hub and not idler enter Chek pages 8.53 and Use 1992 Spes. & Proedures denotes a 13 link wide hain and wide sproket; others are 11 link wide /94

8 Data 1994 MODEL BRAKE TYPE DRIVE TYPE GEARS CHAIN DRIVE SPROCKET POSITION DRIVE Referene Page 8.53 SPROCKET A B C D E DIAMETER Star Lite Star Lite GT Lite Lite Deluxe Lite GT Sport Super Sport M3 M3 M3 M3 M3 H4 H4 2 15/41/ /41/ /39/ /39/ /39/ /35/ /35/ All 1994 models, ex ept WideTrak, the drive shaft is.250" longer and sproket positions are measured to sproket hub and not idler enter Chek pages 8.53 and Sport SKS (Rental) H4 3 16/39/ Trail H4 3 21/39/ Trail Deluxe H4 3 22/41/ H4 3 21/39/ SKS H4 3 20/39/ XCR H5 3 21/39/66W XCRSP WideTrak GT* WideTrak LX* H5 M2 M2 3 21/39/ /41/ /41/ o Classi H4 3 21/39/ EFI H4 3 21/39/ EFI SKS H4 3 20/39/ XLT H4 3 21/39/66W XLT SKS H4 3 20/39/66W XLTSP H /39/66W Classi Touring RXL RXL SKS H4 H5 H5 3 20/39/ /35/64W 3 21/39/66W ) Storm H5 3 23/37/66W Storm SKS H5 3 21/37/66W XCR H5 3 21/39/ Xtra H4 3 21/39/66W "W" denotes a 13 link wide hain and wide sproket; others are 11 link wide. * WideTrak sproket plaement as shown on VIII-39 typial 4 drive with enter idler. 8/94 8.6

9 n I BRAKES I FINAL DRIVE Data C 1995 DRIVE SPROCKET POSITION DRIVE, Referene Page 8.53 BRAKE DRIVE GEARS SPROCKET A B C D E MODEL TYPE TYPE CHAIN DIAMETER o Star Lite M3 2 15/41/ Lite M3 2 16/39/ Lite Deluxe M3 2 16/39/ Lite GT M3 2 16/39/ Sport H4 3 16/35/ Super Sport H4 3 17/35/ Sport Touring H4 3 16/39/ Trail H4 3 21/39/ Trail Deluxe H4 3 22/41/ UC H4 3 21/39/ SKS H4 3 20/39/ XCR H5 3 21/39/66W XCR H5 3 21/39/ WideTrak GT* M2 4 19/41/ WideTrak LX* M2 4 19/41/ Indy 500 H4 3 21/39/ Classi H4 3 21/39/ EFI H4 3 21/39/ EFI SKS H4 3 20/39/ EFI SKS PT H4 3 20/39/ ** XLT H /39/66W XLTSKS H4 3 20/39/66W XLT SKS PT H4 3 20/39/66W 6.16** XLTSP H4 3 21/39/66W XLT Touring H4 3 20/39/66W RXL H5 3 20/35/66W RXL Touring H5 3 21/39/66W Storm H5 3 23/37/66W Storm SKS H5 3 20/35/66W Storm SKS PT H5 3 20/35/66W 6. 16** "W" denotes a 13 link wide hain and wide sproket; others are 11 link wide. * WideTrak sproket plaement as shown on VIII-39 typial 4 drive with enter idler. **8 Tooth drive sproket All 1995 models, exept WideTrak, the drive shaft is.250" longer and sproket positions are measured to sproket hub and not idler enter. Chek pages 8.53 and / /94

10 Hydrauli Brake System Operation E ~ F A D--- The Polaris snowmobile hydrauli brake system onsists of the following omponents or assemblies: brake lever, master ylinder, hydrauli hose, brake aliper (slave ylinder), brake pads, and a brake dis whih is seured to the drive line. When the hand ativated brake lever (A) is applied, it ontats a piston (B) within the master ylinder. As the 0 master ylinder piston moves inward it loses a small opening alled a port within the ylinder and starts to build pressure within the brake system. As the pressure within the system is inreased, the piston (D) loated in the brake aliper moves outward and applies pressure to the moveable brake pad. This pad ontats the brake dis, moves the aliper in its floating braket and pulls the stationary side pad into the brake dis. This ation redues brake dis speed and vehile speed. As the lever pressure is inreased, the braking effet is inreased. The frition applied to the brake pads will ause the pads to wear. As these pads wear, the piston within the aliper self-adjusts and moves further outward. Brake fluid level is ritial to proper system operation. A low fluid level allows air to enter the system ausing the brakes to feel spongy. A high fluid level does not allow enough room for fluid expansion. Both onditions will result in loss of brakes. Loated within the master ylinder is a small port (C) whih is opened and losed by the master ylinder piston assembly. The port is open when the brake lever is released and the piston is outward. As the temperature within the hydrauli system hanges, this port ompensates for fluid expansion aused by heat, or ontration aused by ooling. During system servie, be sure this port is open. Due to the high temperatures reated within the system during heavy braking, it is very important that the master ylinder reservoir have adequate spae to allow for the brake fluid to expand. Master ylinder reservoirs should be filled to the top of the fluid level mark on the inside of the reservoir: Type 1 Master Cylinder 1/8" (.3 m) below lip of reservoir opening; Type 2 Master Cylinder 1/4" (.6 m) below lip of reservoir opening; Type 3 Master Cylinder 1/4" - 5/16" ( m) below lip of reservoir opening. WARNING: Never overfill the reservoir. This ould ause brakes to lok, resulting in severe injury or death. This system also inorporates a diaphragm (E) as part of the over gasket and a vent port (F) loated between the gasket and the over. The ombination diaphragm and vent allow for the air above the fluid to equalize pressure as the fluid expands or ontrats. Be sure the vent is open and allowed to funtion. If the reservoir is overfilled or the diaphragm vent is plugged, the expanding fluid may build pressure in the brake system and lead to brake failure. 8/94 8.8

11 IE! I BRAKES I FINAL DRIVE Type 1 Master Cylinder Overhaul Removal 1. Brake Hose 2. Housing (ylinder) 3. Cover Gasket 4. Cover 5. Cover Srew 6. Pivot Bolt 7. Piston 8. a-ring 9. Seal U-Pak 10. Compression Spring 11. Brake Lever 12. Pivot Bushing 13. Set Srew 14. Washer CAUTION: Due to the ritial nature of these parts and proedures, be sure you have read and understand hydrauli brake operation on page Remove handlebar grip. To assist in grip removal, plug one end of the handlebar and apply air pressure to the opposite end. 2. Remove brake line. Be prepared to ath all fluid in a shop loth. NOTE: Speial are must be used to see that brake fluid does not ome in ontat with any finished surfaes. 3. Loosen brake ylinder set srew and remove ylinder. 4. Remove brake lever. Note position of brake lever pivot bushing. 5. Remove piston assembly, return spring, and washer (item14). Inspetion and Reassembly 1. Always replae a-ring seals, U-pak seals, and over gasket. 2. Apply lean brake fluid onto piston, piston seals and ylinder bore. 3. Install U-pak seal with lip towards bore, and a-ring seal. 4. Install spring seat washer (item 14) into ylinder. 5. Plae spring into piston end and install piston assembly. CAUTION: Use are not to damage the U-pak seal when installing into the ylinder. "- 6. Reinstall brake lever with bushing, bolt and nut. 7. Prior to installing the master ylinder, it is possible to benh bleed by attahing a short, flexible hose to the outlet fitting and bak into the reservoir. Fill the reservoir and slowly squeeze and release the lever until air bubbles no longer appear. 8. Reinstall master ylinder onto handlebar and reonnet brake line. 9. Adjust master ylinder to a level position entered on the handlebar and tighten the set srew. NOTE: The set srew should be adjusted to allow the ylinder to rotate on the handlebar if it should ever be hit hard. 10. After final bleeding, make sure fluid level is 1/8" (.3 m) below the top of the reservoir. 11. Field test mahine, heking for proper braking ation and lever reserve. Lever reserve should be no less than 1/2" (1.3 m) from the handlebar with the lever firmly applied. 12. Rehek unit for any possible fluid leaks. 8.9 No Closer Than 1/2" (1.3 em) Lever Travel 8/94

12 Type 2 Master Cylinder Overhaul 1. Cover Srew, , 2. Cover y Cover Gasket 4. Cylinder Housing 5. Brake Lever Bushing 6. Brake Lever 7. Park Lever Return Spring 8. Pivot Bolt Nut 9. Park Lever 10. Park Lever Pivot Bolt 11. Park Lever Pivot Bushing 19 L Spring Seat Washer 13. Compression Spring 14. U-Pak Seal 15. Piston 16. O-Ring Seal 17. Clamp Bolt 18. Attahing Clamp 19. Lever Pivot Bolt 20. Baffle 21. Baffle Washer Park Brake Lever Lok Optional at ustomer request WARNING: Release park brake lok before driving or brake system failure or fire may result. Apply brake lever to release. Type 2 - Removal 1. Position lean shop loths to ath spilled fluid and remove brake hose. CAUTION: Brake fluid will damage finished surfaes. Do not allow brake fluid to ome in ontat with finished surfaes. 2. Remove brake lamp attahing bolts (Item 17). 3. Remove park brake lever (Item 9) and brake master ylinder lever (Item 6), noting position of bushing, spring, et., for proper reassembly. 4. Using speial servie tool PN , position push rod through small hole in spring seat washer (Item 12) as shown. Remove piston assembly, spring and washer. Type 2 - Inspetions NOTE: Due to the ritial nature of these parts and proedures, be sure you have thoroughly read and understand Hydrauli Brake Operation, page Thoroughly lean all brake parts with hot soapy water. Rinse with isopropyl alohol. Inspet piston for wear or srathes and replae if any are notied. Chek master ylinder bore for srathes or sore marks and replae if any are notied. CAUTION: Whenever inspetion reveals worn, damaged or defetive parts, replaement is neessary in order to avoid serious damage to the mahine or injury to the operator. 5---; ,,-,, 17 PARK BRAKE LOCK RElEASE BEFORE ORIVtNG OR BRAKE SYSTEM FAILURE OR FIRE MAY RESULT. APPLY BRAKE LEVER TO RELEASE. 8/

13 Type 2 Master Cylinder Overhaul Reassembly 1. Always replae a-ring seal, U-pak seal, and over gasket. G 2. Apply lean brake fluid onto piston, piston seals and ylinder bore. 3. Install seals onto piston with the U-pak lip towards the bore. 4. Insert piston assembly into speial tool PN Position speial tool as shown. This tool is used to guide the lip seal into the ylinder bore without damage. 6. Install spring seat washer into bore and plae spring into piston. 7. Install piston (tool installed) into bore. 8. On models with dust seal, install this seal using speial tool PN NOTE: Use stepped end of tool for piston installation and opposite end for dust seal installation. 9. Reinstall brake lever with bushing bolt and nut. 10. Prior to installing the master ylinder, it is possible to benh bleed by attahing a short, flexible hose to the outlet fitting and bak into the reservoir. Fill the reservoir and slowly squeeze and release the lever until air bubbles no longer appear. 11. Reinstall master ylinder onto handlebar and reonnet brake line. 12. Adjust master ylinder to a level position entered on the handlebar and tighten the set srew. NOTE: The set srew should be adjusted to allow the ylinder to rotate on the handlebar if it should ever be hit hard. 13. After final bleeding, make sure fluid level is 1/4" (.6 m) below the top of the reservoir. 14. Field test mahine, heking for proper braking ation and lever reserve. Lever reserve should be no less than 1/2" (1.3 m) from the handlebar with the lever firmly applied. 15. Rehek unit for any possible fluid leaks. No Closer Than 1/2" (1.3 em) Lever Travel o /94

14 Type H1 Brake Caliper Removal and Inspetion 1. Remove hydrauli line. 8e prepared to ath fluid in a shop loth. Do not allow fluid to ome in ontat with painted surfaes. 2. Remove two bolts (A) holding aliper halves together and four braket mounting srews (8). 3. Remove frition pads, noting differene between stationary side and piston side pads. NOTE: When replaing frition pads only, it is important to make room for new pads. The piston must be pushed bak into the slave ylinder bore. Apply Lotite to the two frition pad attahing srews when reinstalling. 4. Remove piston by using ompressed air at the inlet fitting. CAUTION: Wear eye protetion to avoid getting brake fluid in eyes. Cover assembly as shown. 5. Inspet ylinder and piston for soring. Evidene of severe soring in the aliper bore will mean replaing the housing and piston to obtain a proper piston seal. 8/

15 6. Dip piston assembly and O-Ring seal in brake fluid. Assemble seal to piston. 7. Press piston into aliper bore, keeping it square to avoid soring the bore. Push it firmly all the way in. 8. Reassemble unit by reversing 'disassembly proedures. Be sure all omponents are lean and servieable before reassembling. BRAKES I FINAL DRIVE Type H1 Brake Caliper Repair and Assembly 9. Apply Lotite (PN ) on the two aliper arrier bolts and four braket attahing ap srews. 10. Purge system of all trapped air. 11. Inspet system for leaks. 12. Chek aliper unit mount for free floating ation. Caliper must float freely from end to end on arrier bolts /94

16 Type H2 Brake Caliper Removal and Repair 1. Remove hydrauli line. Be prepared to ath fluid in a shop loth. Do not allow fluid to ome in ontat with painted surfaes. 2. Remove spring lips holding pad retaining pins. 3. Remove two bridge bolts (A) holding aliper halves together and four braket mounting srews (B). Replaing Frition Pads The pad is attahed to a pad holder and is replaed as a set. 1. To make room for new pads, the piston must be pushed bak into the aliper bore. Loosen bleeder srew and work piston bak into bore. 2. Take out pad retaining pins and remove worn frition pads. 3. Install new pad holders. Brake pads should be replaed only as a set. 4. With unit reassembled, apply brakes lightly several times to seat the new pads against the dis. 1. Piston Casting 2. Carrier Casting 3. Piston Seal 4. Piston 5. Pad Assembly (2) 6. Seat Insert (2) 7. Brass Adaptor 8. Stop Light Swith 9. Spring Clip (2) 10. Pad Retainer Pin (2) 11. Bleeder Srew 12. Bridge Bolt (2) 13. Spaer Bushing (4) 14. Nut (2) 15. Braket 16. Male Adaptor 17. Ferrule Fitting 18. Female Connetor ~;e~ /

17 IJ! Disassembly BRAKES I FINAL DRIVE Type H2 Brake Caliper Removal and Repair Refer to the exploded view while performing steps below. Numbers in parenthesis orrespond to allouts on exploded view. NOTE: Do not disassemble and further than neessary to make repairs. CAUTION: Protet eyes from fluid. 1. Disonnet hydrauli lines. 2. Disassemble on a lean benh. 3. Open bleed srew (11) and drain brake fluid from aliper assembly. 4. Remove spring lips (9) holding pad retainer pins (10) and remove pins. 5. Remove two bridge bolts (12). 6. Separate astings (1) and (2). 7. Plae aliper with piston down and remove piston (4) from piston asting (1) by applyi ng ompressed air to the hydrauli inlet port. CAUTION: Do not apply too muh air pressure as damage may result to the piston or piston bore. 8. Using a small wooden or plasti stik, work out piston seal (3) from its groove in the piston bore. Disard old seal. CAUTION: To avoid srathing piston or burring edge of seal groove, do not use a metal tool suh as a srewdriver when removing seal. Cleaning and Inspeting Chek all parts for wear or damage and replae as neessary. o 1. Clean all parts with denatured alohol and wipe dry with a lean, lint-free loth. 2. Using an air hose, blowout the drilled passages and bores. 3. Inspet asting ylinder bore for soring, pitting, or orrosion. A orroded or deeply sored asting should be replaed; light sores and stains may be removed. 4. Polish any disolored or stained area with rous loth only. Use finger pressure and rotate the rous loth in the ylinder bore. Do not slide the loth in and out of the bore under pressure. Do not use any other kind of abrasive or abrasive loth. Blak stains on the bore walls are aused by the piston seals and are not harmful. 5. Chek piston to see if it is pitted, sored, or worn. If so, disard and replae the piston. Do not attempt to polish or sand piston. 6. Clean piston with denatured alohol and wipe dry with a lean, lint-free loth. Blow dry with ompressed air. 7. Chek inlet and bleeder hole threads for damage. 8. Inspet seat inset (6) for damage and replae if neessary /94

18 Type H2 Brake Caliper Assembly 1. Piston Casting 2. Carrier Casting 3. Piston Seal 4. Piston 5. Pad Assembly (2) 6. Seat Insert (2) 7. Brass Adaptor 8. Stop Light Swith 9. Spring Clip (2) 10. Pad Retainer Pin (2) 11. Bleeder Srew 12. Bridge Bolt (2) 13. Spaer Bushing (4) 14. Nut (2) 15. Braket 16. Male Adaptor 17. Ferrule Fitting 18. Female Connetor 1. Reassemble unit by reversing disassembly proedures. Be sure all omponents are lean and servieable before reassembling. 2. Dip a new piston seal (3) into lean brake fluid and plae in groove in ylinder bore. Seal should be positioned at one point in groove and then gently worked around groove by hand until properly seated. Never use an old seal. o 3. Coat piston thoroughly with brake fluid and arefully work piston down the bore until bottomed. CAUTION: Apply even fore to avoid oking piston in bore. 4. Examine pads for wear or damage. If pads are worn to less than half the original thikness, install new pad holder assemblies. If pads are not worn or damaged they may be reused. Be sure to reinstall pads in their original positions. If pads are replaed, they must be replaed in sets. 5. Replae pad retainer pin (10) and spring lips (9). 6. Make sure nuts and bolts are lean and dry. Apply Lotite (PN ) to the two aliper arrier bolts and four braket attahing ap srews. Torque aliper arrier bolts to 30 ft. Ibs. (4.14 kg/m). Torque aliper attahing braket ap srews to 8 ft. Ibs. (1.10 kg/m). 7. Purge system of all trapped air. 8. Inspet system for leaks. ) 9. Chek aliper unit mount for free floating ation. 8/

19 , 1. Cover Srew 2. Cover y Cover Gasket 4. Cylinder Housing 5. Brake Lever Bushing 6. Brake Lever 7. Park Lever Return Spring 8. Pivot Bolt Nut 9. Park Lever 10. Park Lever Pivot Bolt 11. Park Lever Pivot Bushing 12. Spring Seat Washer 13. Compression Spring U-Pak Seal 15. Piston O-Ring Seal Clamp Bolt Optional 18. Attahing Clamp at ustomer Lever Pivot Bolt request 20. Baffle 21. Baffle Washer 19 l,- BRAKES I FINAL DRIVE Type 3 Master Cylinder Overhaul 17 o PARK BRAKE LOCK RELEASE BEFORE DRIVING OR BRAKE SYSTEM FAlWRE OR FIRE MAY RESULT. APPlY BRAKE LEVER TO RELEASE. o o Park Brake Lever Lok WARNING: Release park brake lok before driving or brake system failure or fire may result. Apply brake lever to release. Type 3 - Removal 1. Position lean shop loths to ath spilled flu id and remove brake hose. CAUTION: Brake fluid will damage finished surfaes. Do not allow brake fluid to ome in ontat with finished surfaes. 2. Remove brake lamp attahing bolts (Item 17). 3. Remove park brake lever (Item 9) and brake master ylinder lever (Item 6), noting position of bushing, spring, et., for proper reassembly. 4. Using speial servie tool PN , position push rod through small hole in spring seat washer (Item 12) as shown. Remove piston assembly, spring and washer. Type 3 - Inspetion NOTE: Due to the ritial nature of these parts and proedures, be sure you have thoroughly read and understand Hydrauli Brake Operation, page Thoroughly lean all brake parts with hot soapy water. Rinse with isopropyl alohol. Inspet piston for wear or srathes and replae if any are notied. Chek master ylinder bore for srathes or sore marks and replae if any are notied. CAUTION: Whenever inspetion reveals worn, damaged or defetive parts, replaement is neessary in order to avoid serious damage to the mahine or injury to the operator /94

20 Type 3 Master Cylinder Overhaul Type 3 - Reassembly 1. Always replae O-Ring seal, U-pak seal and over gasket. 2. Apply lean brake fluid onto piston, piston seals and ylinder bore. Install seals onto piston positioning U-pak lip (A) towards spring. Snap spring into plae on piston. 3. Install piston assembly into speial senie tool PN until U-pak seal is overed by tool as shown. NOTE: This tool is used to guide the lip seal into the ylinder bore without damage. ) 4. Install spring seat washer into bore. Insert piston, still installed in tool, into bore. Push piston through speial tool. Remove tool. 5. Reinstall brake lever with bushing, bolt and nut. 6. It is possible to benh bleed master ylinder before installing it on mahine. Attah a short, flexible hose from outlet fitting bak into resenoir. Fill resenoir. Slowly squeeze and release lever until air bubbles no longer appear in resenoir. 7. Reinstall master ylinder onto handlebar and reonnet brake line. Adjust master ylinder to a level position entered on handlebar. Torque lamp srews to in. Ibs. 8. Re-bleed brake system. Chek fluid level in resenoir. The Type 3 Master Cylinder should be 1/4" - 5/16" ( m) below lip of resenoir opening. 9. Field test mahine before putting into senie. Chek for proper braking ation and lever resene. With lever firmly applied, lever resene should be no less than 1/2" (1.3 m) from handlebar. 10. Chek brake system for any possible fluid leaks. WARNING: Although snowmobile and ATV master ylinder pistons are very similar, they are not interhangeable. Piston (A) is a snowmobile piston. Piston (8) is an ATV piston. Notie the differene on the lever end of the piston. Using the wrong piston will ause a build up of pressure in the brake system and ould result in a fire. 8/

21 J, BRAKES I FINAL DRIVE Type H3 Brake Caliper Overhaul H3 brake aliper overhaul is primarily the same as H2. However, this unit inorporates a oolant manifold for insulating or ooling the aliper piston. Due to this design, pad replaement and aliper overhaul require slightly different proedures. Listed below are those differenes. Refer to Type H2 Brake Caliper Overhaul for other servie proedures, leaning, inspetion, et. Brake Pad Replaement 1. Remove master ylinder over and gasket. Prepare to ath spilled brake fluid. 2. Fore aliper piston inward (A). 3. Remove four aliper arrier braket attahing bolts (B). 4. Loosen, but do not remove, the two aliper arrier bolts (C). o o 5. Remove brake pad pin spring lips and remove pines. Note these pins hold the pads (A) and oolant manifold (B). 6. Remove brake pads. On some units, area (C) on the hainase may require additional learane. 7. Replae pads whih are worn to more than 1/2 their original thikness. New pad material thikness is.190" (4.8 mm). 8. Reinstall pads, pins, and spring lips using the following sequene. Install one brake pad pin through forward end of aliper, brake ooler and inner brake pad (piston side). Install outer brake pad, align forward end and install pin and pin spring lip. Install rear pin through aliper, ooler, inner and outer brake pad. Install pin spring Clip. Carefully inspet pads and oolant manifold to ensure proper pin installation and positioning. o /94

22 Type H3 Brake Caliper Overhaul The following proedure should be followed to ensure proper alignment between aliper and brake dis. 1. Install and finger tighten four aliper braket attahing bolts (photo 1, B) 2. Pump up brake system. While holding a small amount of pressure in the system, evenly tighten the two aliper arrier bridge bolts (photo 1, e). Torque bridge bolts to 30 ft.lbs. (4.14 kg/m). NOTE: While tightening these bolts, the brake lever will move outward. 3. Again, pump up the brake system and evenly tighten and torque the four aliper arrier braket attahing bolts to 8 ft. Ibs. (1.1 kg/m). 4. With brake lever released, re-torque the four aliper braket attahing bolts (photo 1, B) to 8 ft. Ibs. (1.1 kg/m) and the bridge bolts (photo 1, e) to 30 ft. Ibs. (4.14 kg/m). 5. To ensure proper positioning of the piston seal it is important to move the piston bak into its bore at least 1/4" (.6 m). Then pump brakes and adjust master ylinder fluid level to 1/4" (.6 m) from the top of the ylinder. 6. Test mahine for proper braking performane. Brake Caliper Removal The piston side aliper asting an be removed and servie as outlined in the following proedure. However, if the stationary side arrier asting should need servie, the hainase will have to be removed. 1. Remove oolant reovery tank attahing bolt (A), four aliper braket attahing bolts (8). and two aliper bridge bolts (e). o 2. Note that the aliper halves are separated by two steel spaers (A). As the bridge bolts are removed, these spaers will fall out. 3. Remove brake pads. ) 4. Remove piston side aliper asting (A). Refer to H2 proedures for leaning and inspetion. 8/

23 Type H3 Brake Caliper Overhaul ( Brake Caliper Casting Reinstallation 1. Temporarily install a bridge bolt (A) as shown to align the arrier braket, stationary side asting, and two spaers (8). 2. Position piston side aliper asting and install the remaining bridge bolt as shown (A). NOTE: The bridge bolt installed in step 1. is used to pilot bridge bolt (A) through the spaers, asting and braket. Push bridge bolt (A) through while holding slight tension on bolt (8). 3. Install the forward bridge bolt through braket, piston side asting, spaers, stationary asting, and braket. NOTE: It is extremely important that spaers (A) are positioned properly. 4. Replae brake pads. 5. Reinstall oolant reovery tank and tank retaining bolt /94

24 Type H4 Brake System Servie Maintenane The routine maintenane proedures below are suggested as a means of keeping the brake system in good working order. 1. Clean any dirt from master ylinder over and remove over. 2. Chek fluid level in reservoir. Add new DOT 3 fluid to within 1/4" (.6 m) of the top of the reservoir. Do not overfill. 3. Make sure floating parts move freely and all other parts are mounted seurely. Tighten hardware as required. 4. Inspet for hydrauli leaks and repair any found. 5. Inspet dis surfae ondition. If warped or badly pitted, replae. 6. Chek to see if frition pads are worn to less than 1/32" (.08 m) thik. Replae if they are. 7. Chek brake lever travel. Brake lever should not feel spongy. Replae pads. Bleed or add fluid as needed. Replaing Frition Pads ) 1. Carrier Braket Attahing Bolts 2. Carrier Braket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Swith 7. Brake Pads 8. Brake Line 9. Bleeder Srew 10. Caliper 11. Rope Guide WARNING: The rider's safety depends on orret installation. Follow the proedures arefully Figure 1 1. Clean any dirt from mount braket and bolts. 2. With a 9/16 soket, remove two 3/8 hex bolts and washers from braket. Remove rope guide. NOTE: Do not disonnet brake line. 3. Lift braket and brake assembly off vehile. 4. Slide brake assembly out of braket. Disard old pads and lips. NOTE: Pad and holders must be replaed as a pair. 5. Clean dirt from end of piston and nearby area with a lean shop loth. CAUTION: Protet eyes from brake fluid. 6. Remove reservoir over. Using a hardwood dowel or the flat of a large srewdriver, work piston bak into bore by arefully prying between parts. 8/

25 Type H4 Brake System Servie 1. Carrier Braket Attahing Bolts 2. Carrier Braket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Swith 7. Brake Pads 8. Brake Line 9. Bleeder Srew 10. Caliper 11. Rope Guide NOTE: Pushing the piston bak into the bore will ause the fluid level to rise in the reservoir and possible to overflow. Remove this exess fluid and disard Figure 1 C e 1. Plae new pads with frition material faing eah other into housing. Hole in plae using lips. See illustration. 2. Slide brake assembly into braket until both lips snap into grooves in braket. 3. Clean top of hainase where brake mounts. 4. Separate pads for installation over dis. If brake assembly does not slide easily over the dis with loose pads, work piston bak into bore by arefully prying between parts using a hardwood dowel or the flat of a large srewdriver. 5. Plae brake assembly over dis and push braket into hainase. 6. Replae 3/8 bolts, washers, and rope guide. Torque to ft. Ibs. ( kg/m). 7. Atuate brake several times to set brake pads to proper operating position. 8. Chek for proper fluid level in master ylinder and replae over. 9. Field test at low speeds before putting into regular servie. Disassembly Refer to the exploded view while performing the following steps Remove braket bolts. Disonnet hydrauli line. Disassemble on a lean benh. Open bleed srew and drain operating fluid from aliper assembly. CAUTION: Protet eyes from fluid. Slide brake assembly out of braket and remove old pads and lips. Plae aliper on benh with piston down. Plae a shop loth in front of the piston and remove piston from asting by applying ompressed air to the hydrauli inlet port. CAUTION: Use only enough air to remove piston. Too muh pressure may damage piston or bore. Using a small wooden or plasti stik, work piston seal out from its groove in the piston bore. CAUTION: To avoid srathing bore or burring edge of seal groove, do not use a metal tool suh as a srewdriver. Disard old seal /94

26 Type H4 Brake System Servie Cleaning and Inspetion Chek all parts for wear or damage and replae any found to be defetive. 1. Clean all parts with denatured alohol and wipe dry with a lean, lint free loth. 2. Using ompressed air, blowout the drilled passages and bores. 3. Inspet asting ylinder bore for soring, pitting or orrosion. A orroded or deeply sored asting should be replaed. Light sores and stains may be removed by polishing with a rous loth only. Use finger pressure and rotate the rous loth in the ylinder bore. Do not slide the loth in and out of the bore under pressure. Do not use any other kind of abrasive loth. Blak stains on the piston are aused by the seal and do no harm. 4. Chek piston to see if it is pitted, sored or worn. If so, disard and replae the piston. CAUTION: Do not attempt to polish or sand piston. 5. Clean piston with denatured alohol and wipe dry with a lean, lint free loth. Using ompressed air, blow dry. 6. Chek inlet and bleeder hole threads for damage. 7. Inspet seat insert for damage and replae if neessary. Assembly 1. Reassemble by reversing disassembly proess. Be sure all parts are lean and servieable before reassembling the unit. 2. Coat a new piston seal in lean DOT 3 brake fluid and plae in groove in the ylinder bore. Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated. CAUTION: Never reuse an old seal. 3. Coat piston thoroughly with brake fluid and work down into bore by hand arefully until bottomed. CAUTION: Apply even pressure to avoid oking the piston in the bore. 4. Examine pads for wear or damage. If pad thikness is less than 1/32" (.08 m) install new pad holder assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their original positions. If pads are replaed, replae in sets and make sure the new pads have the same frition material type ode number as the old set. 5. Connet hose or line to aliper. 6. Plae new pads with frition material faing eah other into housing. Hold in plae using lips. 7. Slide brake assembly into braket until both lips snap into grooves in braket. 8. Separate pads for installation over dis. 9. Plae brake assembly over dis and push braket into hainase. 10. Replae 3/8" bolts, rope guide, and washers. Torque to ft. Ibs. ( kg/m). 11. Atuate brake several times to set brake pads to proper operating position. 12. Make sure master ylinder reservoir brake fluid level is 1/4" (.6 m) from the top of the reservoir. Bleeding Eah hydraulic brake is fitted with a bleeder valve. This is " a speial valve whih seals when turned in tight, but whih allows air or fluid to pass out through a hole in the valve nipple when the valve is loosened one turn. 1. Clean any dirt from master ylinder over and remove over. 2. Attah a flexible tube to nipple of bleeder srew on aliper. 3. Plae other end of flexible tube into a jar ontaining a small amount of lean brake fluid. See that end of tube is below fluid surfae to prevent air from getting bak into the system. 4. Loosen bleeder srew. 5. Slowly operate brake and hek for air bubbles rising in fluid, indiating air is being fored out of the system. 6. Tighten bleeder srew as master ylinder is being depressed and reahing end of stroke. 7. Repeat steps 4 through 6 until air bubbles stop, adding new fluid to reservoir as needed: 8. Add new DOT 3 brake flu id to reservoir to bring level bak up to within 1/4" (.6 m) of top. Replae diaphragm and ap. 9. Re-hek system for proper operation and for leaks. 10. Disard fluid in jar. This fluid ontains air and should not be reused. 11. WARNING: Upon ompletion of brake servie, test vehile at low speeds before putting vehile in regular servie. A thorough brake hek should be made every ten days under normal onditions. This hek should be made more often as the pads wear down. Under hard usage, hek the fluid level often. As the brake pads wear, fluid fills the area behind the piston, lowering the fluid level in the reservoir. 8/

27 Type H5 Brake System Servie ( Maintenane The routine maintenane proedures below are suggested as a means of keeping the brake system in good working order. 1. Clean any dirt from master ylinder over and remove over. 2. Chek fluid level in reservoir. Add new DOT 3 fluid to within 1/4" (.6 m) of the top of the reservoir. Do not overfill. 3. Make sure floating parts move freely and all other parts are mounted seurely. Tighten hardware as required. 4. Inspet for hydrauli leaks and repair any found. 5. Inspet dis surfae ondition. If warped or badly pitted, replae. 6. Chek to see if frition pads are worn to less than 1/32" (.08 m) thik. Replae if they are. 7. Chek brake lever travel. Brake lever should not feel spongy. Replae pads. Bleed or add fluid as needed. 8. Chek ooler hose onnetions for leaks and replae hoses as required. Replaing Frition Pads 1. Carrier Braket Attahing Bolts 2. Carrier Braket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Swith 7. Brake Pads 8. Brake Line 9. Bleeder Srew 10. Caliper (Liquid Cooled) 11. Rope Guide 12. Water Cooler Manifold 13. Srews (Cooler Manifold) 12 2 WARNING: The rider's safety depends on orret installation. Follow the proedures arefully. ) 1. Clean any dirt from mount braket and bolts. 2. With a 9/16 soket, remove two 3/8 hex bolts and washers from braket. Remove rope guide. NOTE: Do not disonnet brake line. 3. Remove hose lamp from engine side of ooler. Twist and remove hose from ooler, athing and disposing of antifreeze properly. 4. Lift braket and brake assembly off vehile. Raise open end of ooler and pad assembly to trap antifreeze in ooler. 5. Slide brake assembly out of braket. Disard old pads and lips. NOTE: Pad and spring Clip must be replaed as a pair. 6. Clean dirt from end of piston and nearby area with a lean shop loth. CAUTION: Protet eyes from brake fluid. 7. Remove reservoir over. Using a hardwood dowel orthe flat of a large srewdriver, work piston bak into bore by arefully prying between parts /94

28 Type H5 Brake System Servie 1. Carrier Braket Attahing Bolts 2. Carrier Braket 3. Piston 4. Piston Seal 5. Spring Clip 6. Stop Light Swith 7. Brake Pads 8. Brake Line 9. Bleeder Srew 10. Caliper (Liquid Cooled) 11. Rope Guide 12. Water Cooler Manifold 13. Srews (Cooler Manifold) 12 2 NOTE: Pushing the piston bak into the bore will ause the fluid level to rise in the reservoir and possible to overflow. Remove this exess fluid and disard. 1. Plae new pads with frition material faing eah other into housing. Hold in plae using lips. See illustration. 2. Slide brake assembly into braket until both lips snap into grooves in braket. 3. Clean top of hainase where brake mounts. 4. Separate pads for installation over dis. If brake assembly does not slide easily over the dis with loose pads, work piston bak into bore by arefully prying between parts using a hardwood dowel or the flat of a large srewdriver. 5. Install oolant hose and lamp on ooler assembly. 6. Plae brake assembly over dis and push braket into hainase. 7. Replae 3/8 bolts, washers, and rope guide. Torque to ft. Ibs. ( kg/m). 8. Atuate brake several times to set brake pads to proper operating position. 9. Chek for proper fluid level in master ylinder and replae over. 10. Be sure to bleed oolant system by opening ap lever and running unit until all air in system has been displaed. Fill reservoir and lose ap lever. 11. Field test at low speeds before putting into regular servie. Disassembly {For Caliper or Piston Replaement} Refer to the exploded view while performing the following steps. 1. Remove braket bolts. 2. Disonnet hydrauli line. 3. Disonnet and plug oolant lines, athing and disposing of antifreeze properly. 4. Disassemble on a lean benh. 5. Open bleed srew and drain operating fluid from aliper assembly. CAUTION: Protet eyes from fluid. 6. Slide brake assembly out of braket and remove old pads and lips. 7. Plae aliper on benh with piston down. 8. Plae a shop loth in front of the piston and remove piston from asting by applying ompressed air to the hydrauli inlet port. CAUTION: Use only enough air to remove piston. Too muh pressure may damage piston or bore. 9. Using a small wooden or plasti stik, work piston seal out from its groove in the piston bore. CAUTION: To avoid srathing bore or burring edge of seal groove, do not use a metal tool suh as a srewdriver. 10. Disard old seal. 8/

29 Cleaning and Inspetion Chek all parts for wear or damage and replae any found to be defetive. BRAKES I FINAL DRIVE Type H5 Brake System Servie 1. Clean all parts with denatured alohol and wipe dry with a lean, lint free loth. 2. Using ompressed air, blowout the drilled passages and bores. 3. Inspet asting ylinder bore for soring, pitting or orrosion. A orroded or deeply sored asting should be replaed. Light sores and stains may be removed by polishing with a rous loth only. Use finger pressure and rotate the rous loth in the ylinder bore. Do not slide the loth in and out of the bore under pressure. Do not use any other kind of abrasive loth. Blak stains on the piston are aused by the seal and do no harm. 4. Chek piston to see if it is pitted, sored or worn. If so, disard and replae the piston. CAUTION: Do not attempt to polish or sand piston. 5. Clean piston with denatured alohol and wipe dry with a lean, lint free loth. Using ompressed air, blow dry. 6. Chek inlet and bleeder hole threads for damage. 7. Inspet seat insert for damage and replae if neessary. Assembly 1. Reassemble by reversing disassembly proess. Be sure all parts are lean and servieable before reassembling the unit. 2. Coat a new piston seal in lean DOT 3 brake fluid and plae in groove in the ylinder bore. Seal should be positioned at one point in groove and then gently worked around the groove by hand until properly seated. CAUTION: Never reuse an old seal. 3. Coat piston thoroughly with brake fluid and work down into bore by hand arefully until bottomed. CAUTION: Apply even pressure to avoid oking the piston in the bore. 4. Examine pads for wear or damage. If pad thikness is less than 1/32" (.OS m) install new pad holder assemblies. If pads are not worn or damaged, they may be reused. Be sure pads are reinstalled in their original positions. If pads are replaed, replae in sets and make sure the new pads have the same frition material type ode number as the old set. 5. Connet hose or line to aliper. 6. Plae new pads with frition material faing eah other into housing. Hold in plae using lips. 7. Slide brake assembly into braket until both lips snap into grooves in braket. S. Separate pads for installation over dis. 9. Plae brake assembly over dis and push braket into hainase. 10. Install oolant lines and hose lamps and tighten seurely. 11. Replae 3/S" bolts, rope guide, and washers. Torque to ft. Ibs. ( kg/m). 12. Atuate brake several times to set brake pads to proper operating position. 13. Make sure master ylinder reservoir brake fluid level is 1/4" (.6 m) from the top of the reservoir. Bleeding Eah hydrauli brake is fitted with a bleeder valve. This is a speial valve whih seals when turned in tight, but whih allows air or fluid to pass out through a hole in the valve nipple when the valve is loosened one turn. 1. Clean any dirt from master ylinder over and remove over. 2. Attah a flexible tube to nipple of bleeder srew on aliper. 3. Plae other end of flexible tube into ajar ontaining a small amount of lean brake fluid. See that end oftube is below fluid surfae to prevent air from getting bak into the system. 4. Loosen bleeder srew. 5. Slowly operate brake and hek for air bubbles rising in fluid, indiating air is being fored out of the system. 6. Tighten bleeder srew as master ylinder is being depressed and reahing end of stroke. 7. Repeat steps 4 through 6 until air bubbles stop, adding new fluid to reservoir as needed. S. Add new DOT 3 brake fluid to reservoir to bring level bak up to within 1/4" (.6 m) of top. Replae diaphragm and ap. 9. Re-hek system for proper operation and for leaks. 10. Disard fluid in jar. This fluid ontains air and should not be reused. 11. Be sure to bleed oolant system by opening ap lever and running unit until all air in system has been displaed. Fill reservoir and lose ap lever. 12. WARNING: Upon ompletion of brake servie, test vehile at low speeds before putting vehile in regular servie. A thorough brake hek should be made every ten days under normal onditions. This hek should be made more often as the pads wear down. Under hard usage, hek the fluid level often. As the brake pads wear, fluid fills the area behind the piston, lowering the fluid level in the reservoir S/94

30 Bleeding Proedures for Polaris Brake Systems The Polaris hydrauli brake mehanism onsists of the following omponents or assemblies: handlebar mounted master ylinder, hydraulially operated plunger assembly (slave ylinder) integrally mounted in hainase rear over, adjustable brake pad, and self-aligning brake dis mounted in hainase. The master ylinder ontains a fluid reservoir and a ylindrial pressure hamber. Fore applied to the brake lever is transmitted to the fluid, whih atuates the plunger assembly in the hainase rear over. A oil spring loated in the master ylinder holds the piston assembly against the atuating fore of the brake lever. The piston assembly onsists of a piston, U-seal and rubber a-ring. SERVICE Air in the hydrauli system will ause a springy or spongy ation of the brake lever. Follow diretions below for bleeding. 1. Fill master ylinder reservoir to reommended level with DOT 3 brake fluid PN : Type 1 Master Cylinder 1/8" (.3 m) below lip of reservoir opening; Type 2 Master Cylinder 1/4" (.6 m) below lip of reservoir opening; Type 3 Master Cylinder 1/4"- 5/16" ( m) below lip of reservoir opening. 2. Slip a flexible rubber tube over ball of bleeder valve and diret fluid away from painted areas. CAUTION: Brake fluid will damage finished surfaes. Do not allow brake fluid to ome in ontat with finished surfaes. 3. Slowly squeeze brake lever a full stroke and hold. Unsrew bleeder valve 3/4 turn to release air. Close bleeder valve. Release brake lever. Repeat this proedure until fluid flows from bleeder valve in a solid stream, free of air. Re-hek fluid level in reservoir. J 8/

31 Type M1 Brake Overhaul and Pad Replaement ~ i : I ) 1. Adjuster Bolt and Stop 2. Jam Nut 3. Jam Nut Loking Tab 4. Atuating Lever 5. Helix Shaft 6. Brake Pad Retainer 7. Caliper Casting 8. Moveable Brake Pad 9. Brake Dis 10. Carriage Bolt 11. Stationary Pad Assembly 12. Front Drive Shaft 13. Drive Shaft Bearing Flangette 14. Brake Dis Key 15. Front Drive Sproket 16. Nut, 5/16" 17. Caliper Attahing Bolt (2) 18. Return Spring 19. Cable Sleeve Jam Nut (2) 20. Caliper Attahing Nut (2) 21. Brake Cable Braket 22. Brake Cable 1. Open adjuster bolt jam nut loking tab (A). 2. Loosen jam nut and remove adjuster bolt (B). 3. Remove atuating lever (C) and return spring. 4. Remove two brake aliper attahing nuts (D). 5. Remove able braket and aliper assembly. Chek able ondition at both ends. Frayed or binding brake ables must be replaed /94

32 Type M1 Brake Overhaul and Pad Replaement 6. Slide brake dis off front drive shaft. Chek dis ondition and mounting. Replae if neessary. 7. Clean drive shaft in brake dis area. Lightly lubriate with anti-seize. 8. Remove arriage bolt (A). Remove pad assembly and replae with new assembly. 9. Install brake dis. The dis must float or slide freely on the front drive shaft. 10. Replae moveable pad assembly and install aliper onto attahing bolts. 11. Install brake able braket and torque attahing nuts to 30 ft. Ibs. (4.14 kg/m). 12. Loosen able sleeve jam nuts and adjust brake able sleeve to its shortest position. CAUTION: The following step is ritial for proper positioning of the atuating arm to the aliper helix shaft. 13. With brake lever bottomed on handlebar, and helix shaft (A) bottomed in aliper, install atuating arm, jam nut loking tab, jam nut, and adjuster bolt. 14. Insert a.015" feeler gauge between the brake dis and moveable brake pad. Release brake lever. Install return spring and finger tighten bolt. Set adjuster bolt jam nut, bend loking tab, and remove feeler gauge. 15. Field test unit for proper braking ation. 8/

33 Type M2 Exploded View 6 2 L 1 / r -1\ 2\ L 24 ~ I I..J I 01 (~, Brake Cable 2. Cable Sleeve Jam Nut (2) 3. Bridge Bolt (2) 4. Brake Cable Braket 5. Spaer Bushing (4) 6. Carrier Braket 7. Nut (2) 8. Brake Pad (2) 9. Caliper Casting 10. Return Spring 11. Nut 12. Cable Clevis 13. Clevis Bolt 14. Adjuster Bolt 15. Adjuster Bolt Stop 16. Jam Nut 17. Jam Nut Loking Tab 18. Bushing 19. Atuating Lever 20. Helix Shaft 21. Pad Baking Plate 22. Caliper Casting 23. Braket Cap Srew (4) 24. Lok Washer (4) 25. Snap Ring (2) 26. Brake Dis 27. Key 28. Jakshaft /94

34 , a. BRAKES I FINAL DRIVE Type M3 Exploded View 1. Cable, Brake 2. Braket, Brake 3. Washer 4. Washer, Spring Lok 5. Bolt 6. Braket, Brake Top Mounting 7. Bushing 8. Nut, Bi-Lok 9. Spaer, Alignment 10. Caliper, Stationary, Cast 11. Pad, Brake 12. Puk, Moveable Brake 13. Spring, Brake Return 14. Nut 15. Bushing, Brake Arm 16. Bolt 17. Clevis, LT 18. Bolt 19. Retaining Ring 20. Brake Dis 21. Seal 22. Jakshaft 23. O-Ring ~1 I B A C D Adjusting Proedure CAUTION: Whenever inspetion reveals worn, damaged or defetive parts, replaement is neessary in order to avoid serious damage to the mahine or injury to the operator. 1. Open adjuster bolt jam nut loking tab (A). Loosen jam nut and remove adjuster bolt (B). 2. Remove atuating lever (C) and return spring. 3. Remove top mount braket and brake assembly mounting bolts (Item 5). Remove washers (Items 3 and 4) and alignment spaers (Item 9). Remove brake assembly. NOTE: Be prepared to ath brake pads as assembly is lifted out. 4. Remove brake pads and inspet for wear and damage. Replae if neessary. 5. Inspet rotor dis and replae if neessary. NOTE: Reassembly is made easier by lipping moveable brake pad into position under holder lip. Stationary pad an be held in plae by use of a rubber band while plaing assembly over rotor dis and mounting to hainase. 6. Install alignment spaers (Item 9), washers (Items 3 and 4) and bolts (Item 5). Torque assembly to ft. Ibs. 7. Loosen able sleeve jam nuts and adjust brake able sleeve to its shortest position. WARNING: The following step is ritial for proper positioning of the atuating arm to the aliper helix shaft. Improper positioning will result in minimal resistane and ineffetive brakes. 8. With brake lever bottomed on handlebar and helix shaft (D) bottomed in aliper, install atuating arm, jam nut loking tab, jam nut and adjuster bolt. 9. Insert a.015" (.04 m) feeler gauge between brake dis and moveable brake pad. Release brake lever. Install return spring and finger tighten bolt. Set adjuster bolt jam nut, bend loking tab and remove feeler gauge. 10. Field test mahine for proper braking ation before putting into servie. 8/

35 n n r) OJ W w ex> -- CD """ INDY JACKSHAFT SPEED VS. MILES PER HOUR SPROCKET COMBINATION/GEAR RATIO/CHAIN PITCH The following hart should be used to selet optimum gearing for speial appliations. The hart is alulated for models with the P85 drive luth at a 1 to 1 ratio between drive luth and driven luth front drive sproket diameter is 7.06 inhes. To use the hart, selet the jaks haft rpms (equal to engine rpm). MPH is shown to the right of jakshaft rpm. Shown on top is optimum gearing for mph and engine rpms. 20/39 20/4 1 Jakshaft 23/ / / / /39 15/ / / /39 14/40 14/41 RPM Pilh " 64 " , " : ; , , , ,1 842_ I:\,) o ~ =r C\,)m =:0 C/)> "0" mm.c/) <- C/)!! s:z "tj» ::e' Oe 1:\,)< =r2:! ~m

36 Type 1 Drive System Overhaul 1. Remove drive belt, driven luth and driven luth spaer washers. 2. Open adjuster bolt jam nut loking tab (A). Loosen jam nut and remove adjuster bolt (8). 3. Remove atuating lever (C) and return spring. 4. Remove two brake aliper attahing nuts (D). 5. Remove able braket and aliper assembly. Chek able ondition at both ends. Frayed or binding brake ables must be replaed. 6. Slide brake dis off front drive shaft and remove half moon key. 7. Remove four suspension mounting bolts and suspension. Note plaement of two rear torque arm idler wheel thrust spaers for reassembly. 8. Loosen lok ollar Allen head set srew. With a punh and hammer, loosen bearing lok ollar loated on brake end of drive shaft. 9. Remove three flangette attahing bolts (A). NOTE: The longest of these bolts attahes the stationary brake pad. 10. Slide drive shaft toward brake side of hassis until driven luth end is free. Tilt shaft and remove it from brake end bearing. 11. Remove trak. o 8/

37 Type 1 Drive System Overhaul 12. Before reassembly hek drive shaft, drive shaft sproket, and drive shaft bearings. Replae if neessary. 13. Reverse disassembly proedures to reassemble. Sproket or drive shaft entering is ontrolled by the hex portion of drive shaft (A) being bottomed on driven luth side bearing (B). NOTE: Driven luth must be installed and torqued before lok ollar is tightened. 14. Refer to brake adjustment proedures in this hapter. o /94

38 Type 2 Drive System Overhaul Disassembly 1. Remove hood. 2. Remove air silener and exhaust system. NOTE: Exhaust silener and expansion hamber an be removed as a unit. 3. Remove drive belt and driven luth, noting position of l uth offset washers. 4. Loosen jakshaft bearing loking ollar and slide it away from bearing. 5. Remove three flangette attahing nuts and washers loated on left side of front drive shaft. 6. If unit is equipped with a battery, remove the battery. 7. Drain or siphon fuel tank. 8. Remove four suspension mounting bolts. 9. Plae a protetive mat on the floor and tip the mahine on its left side. 10. Remove suspension. 11. Loosen front drive shaft loking ollar set srew. Rotate bearing lok ollar and slide it away from bearing. ) 12. Remove four aliper attahing braket apsrews (A) and three hainase over bolts (8). J 8/

39 Type 2 Drive System Overhaul 13. Loosen hain adjuster bolt jam nut and remove adjuster. 14. Remove hain, and top and bottom gears. Note position of gear spaer and shims for proper gear alignment upon reassembly. 15. Remove three hainase attahing nuts and arriage bolts (A). 16. Install a 5/16 x 3/4" bolt into the jakshaft and drive the shaft out through the upper ase bearing. 17. Remove front d rive shaft and trak. 18. Remove stop light swith wires and lift brake aliper assembly from brake dis. CAUTION: Do not squeeze brake lever with aliper removed. 19. Remove three flangette attahing bolts from left side of jakshaft. NOTE: The bottom flangette is aessible from the underside of the tunnel as shown in the photo at right. 20. Remove jakshaft /94

40 Type 2 Drive System Overhaul Inspetion 21. Inspet jakshaft bearing in support area as shown. If any wear is noted, the shaft must be replaed Remove brake dis and inspet brake dis key and keyways. If the key or keyways show signs of wear, the brake dis and jakshaft should be replaed. If the brake dis is glazed, it should also be replaed. 23. Lubriate jakshaft between snap rings with anti-seize and reinstall brake dis. Reassembly Be sure all parts are lean and servieable before proeeding with reassembly. It is important that the following reassembly steps be performed in sequene to prevent misalignment and possible omponent failures. 1. Remove and replae upper and lower hainase bearings. 2. Replae hainase over gasket. Use a small amount of silione sealer at the ends of the over gasket. 3. Install jakshaft as shown and plae aliper assembly onto brake dis. 4. Plae hainase into position on bulkhead and onto jakshaft. Do not bolt hainase to bulkhead at this time. 5. Install jakshaft alignment tool with bolt and washer as shown. Tighten alignment tool bolt until jakshaft is seated into upper hainase bearing. 8/

41 6. Install and tighten three hainase attahing arriage bolts and loking nuts. 7. Apply Lotite to four aliper attahing braket apsrews and finger tighten into arrier braket. With brake applied, torque apsrews (A) to 8 ft. Ibs. (1.1 kg/m). 8. Reinstall stop light swith wires. 9. Install a flangette into left bearing support hole. BRAKES I FINAL DRIVE Type 2 Drive System Overhaul o 10. With alignment tool torqued to 6 ft. Ibs. (.83 kg/m), the shaft should be entered as shown. If not, the hainase will have to be shimmed between the bulkhead and ase. Using Shim Kit PN , install shims as needed to position shaft on enter. 11. Install trak and front drive shaft assembly. 12. Remove jaks haft alignment tool and install top and bottom gear shims, hain and gears. 13. Tighten gear retainer bolts. Chek gear alignment and hain tension. 14. Install bearing assembly onto left side drive shaft and tighten three arriage bolts. 15. Lightly rotate bearing loking ollars on jakshaft and drive shaft. Tighten Allen head set srews /94

42 Type 2 Drive System Overhaul 16. Add three ounes of Polaris hainase oil into the hainase and reinstall hainase over. NOTE: One full stroke on the pump equals one oune of oil. Polaris highly reommends the use of this oil for extended gear and hin life. 17. Install over and fill to hek plug opening. 18. Reinstall suspension. Torque suspension mounting bolts to ft. Ibs. ( kg/m). 19. Reinstall air silener, exhaust system and driven luth. Chek and adjust luth offset. Refer to Chapter 7 for orret offset speifiations and tool. CAUTION: If this step is not performed, bearing side loading and luth misalignment during driven luth bolt tightening may our. ) 20. With driven luth properly positioned, measure distane between alignment spaer (A) and outer edge of driven luth hub (8). This distane must be taken up by using washer(s) PN (C). 21. Reinstall luth retaining bolt and torque to 12 ft. Ibs. (1.66 kg/m). 22. Reinstall drive belt. 23. Reinstall hood and field test unit for proper front drive operation. 8/

43 Type 3 Drive System Overhaul 1. Remove hood, air silener, exhaust system and battery, if so equipped. 2. Turn fuel valve off. 3. Remove drive belt and driven luth. Note position of washers for ontrolling drive to driven offset (A) and washers to ontrol luth free floating (8). 4. Loosen jakshaft bearing lok ollar set srew. Loosen lok ollar by rotating in opposite diretion of rotation. 5. Remove two upper flangette attahing bolts (A). 6. Remove three bolts seuring angle drive and bearing flangettes. 7. Remove four suspension mounting bolts. 8. Plae a protetive mat on floor and tip mahine onto left side. 9. Remove rear suspension. 10. Position trak as shown and remove third jakshaft flangette attahing bolt (A). 11. Loosen drive shaft lok ollar set srew and rotate lok ollar /94

44 Type 3 Drive System Overhaul 12. Remove hainase over attahing bolts and remove over. 13. Remove astle nut otter pin and astle nut. 14. Remove hain adjustment bolt and hain tensioner assembly. 15. Remove bottom gear attahing bolt, hain and sprokets. 16. Note position of top gear spaer (A) and gear alignment washers (8). Remove spaer and washers. 17. Remove four bolts seuring aliper arrier braket to hainase (A). 18. Remove three hainase to bulkhead attahing nuts and bolts. NOTE: On some mahines it may be neessary to remove the rear exhaust braket (8) prior to lifting hainase or removing drive shaft assembly. 8/

45 Type 3 Drive System Overhaul 19. Remove hainase and slide brake aliper assembly (A) outward from brake dis as shown. 20. Remove oil tank attahing bolt (A). On liquid ooled models, remove oolant reovery tank bolt (B). 21. Raise jakshaft assembly as shown. 22. Remove a-ring, seal sleeve and brake dis by tapping on jakshaft end with a soft fae hammer as shown. 23. Remove jakshaft and drive shaft. 24. Inspet drive shaft and jaks haft in bearing ontat area. If diameter is.001" (.025 mm) less than non-ontat area, shafts should be replaed. 25. Remove bearing retaining snap rings /94

46 Type 3 Drive System Overhaul 26. Pry out old seal. 27. Press out old bearing from side shown. NOTE: If bearing appears tight, use heat to expand hainase bore. 28. Apply Lotite 680 (PN ) to outer rae of bearing and press into position. 29. Reinstall snap rings. 30. Press new seals in until outer edge is flush with hainase shoulder. 31. Install drive shaft and jakshaft as shown with new seal sleeves (A) and O-Rings. NOTE: Reessed area on seal sleeve is positioned outward and O-Ring rests in this reess. 32. Grease seal sleeves and O-Rings. 33. Reinstall brake aliper onto brake dis and install hainase. NOTE: On some models, prior to installing the drive shaft it will be neessary to install the hainase to bulkhead attahing bolts (A). 34. Install jaks haft alignment tool (PN ) and seure with astle nut as shown. 8/

47 Type 3 Drive System Overhaul 35. Slide a bearing onto driven luth end and hek shaft alignment to bulkhead opening (A). 36. If alignment is not orret, shims may be added between any of the hainase to bulkhead attahing paints. Use Shim Kit PN Reassemble by reversing disassembly proedures. 38. Torque astle nut to 50 ft. Ibs. (6.9 kg/m).. If otter pin does not align, tighten nut until otter pin aligns. 39. Finger tighten four arrier braket attahing bolts. 40. Apply parking brake to align aliper to brake dis. Torque bolts with brake applied. Release brake and retorque bolts to 8 ft. Ibs. (1.1 kg/m) /94

48 Type 3 Drive System Overhaul Maximum sproket and hain life are diretly related to proper sproket alignment and hain tension. 41. Before installing drive hain, plae a straight edge against upper and lower installed sprokets. The edge should ontat equally on both sprokets. 42. If misalignment is evident, the addition or subtration of washers (PN ) behind the bottom sproket will be neessary. 43. To obtain orret hain tension, plae a slight reverse tension on the hain as indiated in the illustration at right (A). 44. There should be approximately 1/4-3/8" ( m) defletion on the hain at point (B). Loosen adjuster bolt loknut and turn adjuster bolt (C) until orret hain defletion is obtained. 45. Lok adjuster bolt loknut while holding a wrenh on the adjuster bolt. 46. Install hainase over and add Polaris hainase lubriant (PN ) through over upper plug hole until lubriant trikles from hek plug hole. 47. Reinstall plugs. 8/

49 48. The illustration at right shows a ross setion view of the upper hainase. Always replae seals and O-Rings. Chek seal sleeve for wear and/or niks. Replae if any are notied. 49. Castle nut is torqued to 50 ft. Ibs. (6.9 kg/m). Cotter pin must be installed and fixed so it will not hit hainase over. NOTE: If otter pin does not align, tighten nut until alignment is ahieved. BRAKES I FINAL DRIVE Type 3 Drive System Overhaul 50. When install aliper assembly, tighten four braket attahing bolts (A) finger tight. 51. Apply brakes and torque to 8 ft. Ibs. (1.1 kg/m). Release brakes and retorque to 8 ft. Ibs. (1.1 kg/m). This proedure allows better alignment of brake aliper to brake dis. 52. When reinstall drive shaft flangettes and speedometer angle drive, always replae drive key (A) and install a new gasket (8). 53. Chek able routing and lubriate with Polaris luth and able lube PN Grease angle drive and bearing with Polaris low temp grease. 55. When reinstalling jakshaft flangette and bearing be sure to align bearing outer rae hole (A) with flangette hole (8). This wi" allow a more positive grease entry into the bearing /94

50 Type 3 Drive System Overhaul 56. Lubriate top bearing using a needle point adaptor and Polaris low temp grease. 57. Jakshaft and drive shaft loking ollars are tightened only after hainase top and bottom gears have been torqued. Lightly rotate ollars in the same diretion as the shaft rotates and tighten set srew. 58. When driven luth offset is properly adjusted, the washers (A) PN are used to adjust for free float on driven. Without a slight free float, the jaks haft bearings ould be side loaded and ause premature bearing failure. 59. If only the jakshaft needs servie, loosen left rear nosepan to foot rest mounting bolts and slide shaft out left side without removing hainase. 60. For reassembly, use jakshaft installation tool (A) PN Grease tool and guide jaks haft through brake dis hub, seal sleeve, O-Ring and bearing. NOTE: Jakshaft with tool installed must slide freely. If not, reposition O-Ring. 61. Field test mahine and hek for proper braking ation and drive train effiieny. 8/

51 Type 4 Drive System Overhaul Jakshaft and Drive Shaft Disassembly 1. Remove rear suspension. 2. Clean, lubriate and inspet. 3. Loosen drive shaft lok ollar set srew (A) and rotate ollar. 4. Remove luth guard, drive belt, driven luth, driven luth offset washers and air silener., 5. Remove jakshaft and drive shaft bearing flangette attahing bolts. 6. Remove drive shaft and jakshaft. o 7. Remove bearing from eah shaft and inspet bearing support area (A). If this area shows any sign of wear the shaft must be replaed. ) /94

52 Type 4 Drive System Overhaul 8. Chek shafts at the splined oupling ends. If exessive wear or play is noted here and inside the oupling, the shafts and ouplings should be replaed. NOTE: If this wear is premature, it is very important to hek jakshaft alignment. 9. If the transmission is to be removed, refer to transmission overhaul proedures at the end of this hapter. 10. Move ollar (A) tight against oupler and set. 11. Lubriate drive shaft oupling and shaft splines with grease. NOTE: On 1992 to urrent models, the oupler is greasable. 12. Install oupler with O-Rings, positioning oupler shallow reessed end towards transmission. T A o 13. Install drive shaft through bulkhead and onto transmission output shaft. 8/

53 Type 4 Drive System Overhaul 14. Lubriate flangette and outer rae of bearing. 15. Install bearing lok ollar, inner flangette, new bearing and outer flangette onto drive shaft. 16. Install speedometer drive key, angle drive and attahing bolts, washers, and nuts. Tighten. \. 17. Tightly position bearing lok ollar against bearing inner rae. Tighten Allen head set srew while pulling up on drive shaft in diretion shown /94

54 Type 4 Drive System Overhaul Jakshaft Alignment 18. Lubriate jakshaft oupling and splines with multi-purpose automotive hassis grease. 19. Install jakshaft through bulkhead and onto transmission input shaft. 20. Orbit shaft in bulkhead bearing support opening. NOTE: There should be an equal distane between shaft and bulkhead bearing support during this orbit. 21. To orret any jakshaft misalignment, shim transmission between bulkhead and transmission (A). Use Shim Kit PN See illustration at right for possible shim loations. 22. Clean bearing support area with Lotite Primer T. Install a stud and bearing mount on shaft in bearing area. 23. Install new bearing, outer flangette and flangette attahing bolts. 24. Install driven luth and hek driven luth offset. 25. Torque driven luth bolt to 12 ft. Ibs. (1.66 kg/m). 26. Reinstall rear suspension, drive belt, air silener, and luth guard. 27. Field test for proper operation. 8/

55 Drive Shaft Sproket Installation Tips Refer to brake and drive data pages at the beginning of this hapter for speifi distane from shaft end to sproket idler enter. Diret drive units are measure from Sprokets must be started from the end luth end while all others are measure that has a smooth entry onto the hex from splined end of shaft. portion of the shaft (A). Prior to pressing sprokets, lean shafts with sandpaper to remove rust. Replae shaft if niked or damaged. When pressing new sproket onto shaft, press in hub or enter of sproket. To ensure proper sproket tooth alignment, be sure the vendor logos are oriented in the same position on all sprokets. NOTE: Some diret drive sprokets require the reessed area on the sproket idler be positioned towards the driving side of the sproket tooth. r----- B - A------, -~- SPLINED END Typial 2 Drive Sproket Typial Diret Drive Shaft f D f C i f <, I E D f---- C A ) Typial 4 Drive Sproket Typial 4 Drive with Center Idler o /94

56 Drive Shaft Sproket Installation Tips Driveshaft Sproket Installation Tips, 1993 to Current 1993 to urrent models, exept Wide Traks, have a longer spline on the hainase end of the jakshaft and drive shaft. Drive shaft sproket positions are measured to sproket hub edge instead of sproket idler enter to Current 2 Drive Sproket 1993 to Current 4 Drive Sproket 8/

57 Series 300 Transmission Overhaul Transmission overhaul should also inlude drive system overhaul. After removing drive shaft and jakshaft, proeed as indiated below. 1. Remove four aliper arrier attahing bolts (A). 2. Remove two aliper bridge bolts (8). 3. Remove brake aliper and brake dis. 4. Remove shift linkage (A) and stop light swith wires (8). 5. Remove exhaust system. 6. Remove three nuts seuring transmission to front bulkhead. Remove transmission. NOTE: Note position of transmission shims for reassembly (A). these shims ontrol jakshaft alignment. 7. Remove transmission drain plug (A) and drain oil /94

58 Series 300 Transmission Overhaul 8. Plae transmission as shown and remove shift lever and key (A), neutral light swith (B), detent set srew, spring, and ball (C). 9. Loosen hain tensioner jam nut and remove tensioner bolt. 10. Remove transmission housing attahing bolts (A). 11. Lift upwards on inner housing and tap with a soft fae hammer on input shaft, output shaft, and shift shaft. 12. Remove high range long silent hain (A). 8/

59 13. Remove input luster and shift luster as an assembly (A). BRAKES I FINAL DRIVE Series 300 Transmission Overhaul 14. Remove output luster (A), reverse luster (B) and silent hain as an assembly. 15. Remove low range luster (A). 16. Thoroughly lean and inspet all parts. Refer to orret parts book for replaement parts. 17. Reverse disassembly proedures for reassembly. Transmission Servie Tips Before reassembly, remove all oil seals, and hain tensioner bolt. After transmission is assembled, install tape around shaft splines and shaft sealing area. Grease seal inner and outer diameters. Grease shift shaft O-Ring. These preautions will protet the seals and O-Ring from damage /94 ~ iii.",

60 Series 300 Transmission Overhaul Transmission Servie Tips Be sure the ase half mating surfaes are lean and free of any niks or srathes. Plae a small amount of Lotite 515 Gasket Eliminator (PN ) on one of the ase halves. Install bearings and seals using servie tool PN Bearings, gears, et., are assembled until they bottom onto eah other or onto snap rings or shoulders. Install detent ball and spring. Apply a medium strength thread loking ompound to the Allen head set srew and install it to a depth of " (1.5-3 mm) below the asting surfae. During field testing, hek the detent preload. If the detent is adjusted too tightly, the unit will beome hard to shift. If the detent is too loose, it will affet the operator's pereption of the shift position..06/.12 To adjust hain on HilLo range transmissions, loosen lok nut on adjuster bolt (A). Plae slight reverse tension on hain by turning brake dis, then tighten adjuster bolt (B) to 20 inh. Ibs. Bak bolt off 1 1/4 to 1 1/2 turns and tighten jam nut while holding adjuster bolt. 8.58