9.34
BRAKES
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Pedal Removal and Installation
1. Remove the RH footwell to gain access to the rear
master cylinder.
2. Remove the cotter key.
3. Remove the washers, bushings, and tension spring.
4. Reverse the steps for installation, use a new cotter
key during
installation.
TROUBLESHOOTING
Brakes Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch
Lever Vibration
• Disc damaged
• Disc worn (runout or thickness variance exceeds
serv
ice limit)
Caliper Overheats (Brakes Drag)
• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal inc
orrectly adjusted
• Brake lever or pedal binding or unable to return
fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
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