6.9
BRAKES
6
9923983 - 2012-2013 RZR 170 Service Manual
© Copyright 2012 Polaris Sales Inc.
BRAKE PEDAL
Brake Pedal Removal
1.
Refer to Fig. 2 for pedal removal.
2.
Disconnect both springs (A).
3.
Remove cotter pin (B) and clevis pin (C).
4.
Remove E-clip (D) and washer (E) from pedal mount.
5.
Remove pedal assembly with bushings (F) and sleeve
(G). Visually inspect pedal, bushings, and sleeve for
wear and replace as required.
Pedal Installation
1.
Apply Polaris Premium All Season grease to pivot
post and install pedal with bushings and sleeve.
2.
Install washer and a new retaining E-clip.
3.
Align pedal with master cylinder clevis and install pin.
4.
Install washer and a new cotter pin.
5.
Connect brake light switch spring and pedal return
spring.
6.
Push and release brake pedal to be sure linkage rod
and pedal mechanism returns fully when pedal is
released.
7.
Inspect brake pedal travel. See “Brake Pedal
Inspection / Adjustment” on page 6.9.
Brake Pedal Inspection / Adjustment
1.
Push and release brake pedal. Verify master cylinder
actuator rod and pedal mechanism returns fully and
pedal contacts pedal stop (on left side of pedal pivot
bracket) when released.
2.
If pedal does not return freely, remove pedal and
lubricate. parts. See “Brake Pedal Removal” on
page 6.9.
Pedal Free Play and Pedal Travel
1.
Place vehicle on a flat, level surface.
2.
Shift transmission into Neutral.
3.
Carefully lift rear tires off the ground with a stable
platform jack, or set vehicle on stable jack stands.
4.
While rotating the rear wheels by hand, measure
brake pedal movement before any braking occurs
(Free Play), and record.
5.
Measure the total brake pedal movement before
brake is firmly applied (Pedal Travel).
6.
The pedal should move at least 1/4 inch before any
braking occurs, and no more than 1 - 1 1/2 inch before
brakes are firmly applied. See Fig.1.
7.
If pedal travel is excessive, or if brake pedal feels
spongy and not firm, inspect brake fluid level in the
reservoir, inspect system for leaks, inspect caliper
mounting bolts, disc mounting bolts to be sure they are
tight, and bleed the brake system. See “BRAKE
BLEEDING / FLUID CHANGE” on page 6.7.
Brake Pedal Travel:
1/2-3/4” (12-18mm)
A
C
D
E
F
B
G
Pedal Travel
Fig. 1
1 - 1 1/2 in. (25-37mm)
1/4 in. (6mm) Minimum