Polaris 600 EDGE RMK, Service Manual

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BRAKES / FINAL DRIVE
8.23
Hydraulic Brake Cleaning and Inspection
Check all parts for wear or damage and replace as required. Always replace caliper piston seal and dust seal
(where applicable).
1. Clean all parts with denatured alcohol and wipe dry with a clean, lint free cloth.
2. Using compressed air, blow out the drilled passages and piston bore. Be sure piston seal groove is thoroughly
clean and free from corrosion or brake fluid build up.
3. Inspect piston bore for scoring, pitting or corrosion. A corroded or deeply scored casting should be replaced.
Light scores and stains may be removed by polishing with a crocus cloth only . Use finger pressure and rotate
the crocus cloth in the cylinder bore. Do not slide the cloth in and out of the bore under pressure. Do not use
any other kind of abrasive cloth.
4. Check piston to see if it is pitted, scored or worn. If so, discard and replace the piston.
CAUTION:
Do not attempt to polish or sand piston.
5. Clean piston with denatured alcohol and wipe dry with a clean, lint free cloth. Using compressed air, blow dry.
6. Check inlet and bleeder hole threads for damage. Be sure bleeder screw is clear.
7. Inspect brake line seat for damage and replace caliper if necessary.
Hydraulic Brake Assembly
1. Reassemble by reversing disassembly process. Be sure all parts are clean and serviceable before
reassembling the unit.
2. Coat a new piston seal in clean DOT 3 brake fluid and place in groove in the caliper piston 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 carefully with a rotating motion until bottomed.
CAUTION:
Apply even pressure to avoid cocking the piston in the bore.