Polaris 800 RMK ASSAULT 2011 User Manual

5.31
Final Drive/Brake System
5
Brake Disc Replacement
NOTE: Reference Brake Disc Hardware table before
reinstalling brake disc.
1. Engage the parking brake. Loosen the brake disc bolt.
2. On models equipped with the
QuickDrive™ system,
follow the procedure for removing the drive belt and
sprockets.
3. Disengage the parking brake.
4. Remove the brake caliper from the chaincase or
ba
cker plate. Tie the caliper to the overstructure. Do
not allow the brake caliper to hang from the brake
hose.
5. On QuickDrive™ models, remove the brake disc.
6. Remove the brake disc bolt, beveled washer and shim
washe
r(s) if model is equipped with the phantom
brake caliper.
7. Remove the brake disc from the jackshaft.
Brake Disc Service Specifications:
• Lateral Run-Out Service Limit = .010" (.254mm)
• Service Limit Thickness = .03
0" (.762mm) less
than nominal
• Nominal Thickness = .197"±.005" (5±.127mm)
8. Prior to installation, clean brake disc with brake
cle
aner, or denatured alcohol. Dry with compressed
air or lint-free towel.
9. Install brake disc on to jackshaft. Reinstall correct
br
ake disc hardware.
NOTE: Brake discs on QuickDrive™ models feature a
d
irectional arrow that must be viewed from the
outside of the vehicle. Arrow points in the direction of
forward travel.
10. Reinstall the brake caliper assembly. Torque caliper
bolts to
specification.
11. Lock the parking brake. Torque brake disc or upper
sprocket bolt to s
pecification.
12. Test brake system prior to returning vehicle to service.
YEAR/
CALIPER TYPE
BRAKE
DISC FASTENER HARDWARE
2010/
Phantom
Fastener: 29 ft-lbs (40 Nm)
Flat Washer
1-2 Float Washers
(Install QTY. to achieve .8mm Disc Float)
2011-Current/
Phan
tom
Fastener: 40 ft-lbs (54 Nm)
Flat Washer
Wave Washer
1 Float Washer
2011-Current/
Ph
antom Lite
Fastener: 40 ft-lbs (54 Nm)
Domed Washer (Dome facing out.)
QuickDrive
™
Upper
Sprocket
Fastener: 30 ft-lbs (40 Nm)
Domed Washer (Dome facing out.)
= T
Brake Caliper Bolts:
40 ft-lbs (54 Nm)
Brake Caliper Bolts (QuickDrive™):
18 ft-lbs (25 Nm)
= T
Brake Disc Bolt:
2010: 30 ft-lbs (40 Nm)
2011-CURRENT: 40 ft-lbs (54 Nm)
QuickDrive™ Upper Sprocket Bolt:
30 ft-lbs (40 Nm)
ARROW

Polaris 800 RMK ASSAULT 2011 Specifications

General

Brand	Polaris
Model	800 RMK ASSAULT 2011
Category	Snowmobiles
Language	English