Polaris 2005 Sportsman MV7, Service Manual, Page: 254 / 312

BRAKES
9.22
REAR (AUXILIARY) BRAKE
REMOVAL / INSTALL
Brake Pedal Removal / Install
1. To remove the brake pedal:
S
Remove the spring attached to the
transmission park lock mechanism
S
Remove the cotter key
S
Remove the washers, bushings, and
tension spring
2. Reverse the steps for installation, use a new
cotter key during installation.
Rear Brake Master Cylinder Removal /
Install
1. If necessary, remove the rear brake line from the
master cylinder. Use a suitable container to catch
the brake fluid. Dispose of brake fluid properly.
2. Remove the two bolts that secure the rear master
cylinder to the brake mount plate. Replace parts
as needed.
3. To install the rear brake master cylinder, mount
the master cylinder to the mount plate and torque
bolts to 8 ft.lbs. (11 Nm).
4. Reinstall the brake line and torque the banjo bolt
to 15 ft.lbs. (21 Nm). If the rear brake line is the
pipe fit style, torque the fitting to 12--15 ft. lbs.
(16--20 Nm).
REAR AUXILIARY MASTER CYLINDER ASSEMBLY
Brake Reservoir
Rear Foot Brake Line
Foot Pedal
Cotter Pin
Washer
Bushing
Mount Plate
Rear Master Cylinder
MC Bolts
Mount Plate Bolts
15 ft.lbs.
(21 Nm)
8 ft.lbs.
(11 Nm)
8 ft.lbs.
(11 Nm)