Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 41

 

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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Instruction - part 41

 

 

6.20

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Brake Fluid Replacement & Bleeding

This procedure should be used to change fluid or bleed
brakes during regular maintenance, or after complete
brake service. Brake fluid may damage painted or plastic
surfaces. Take care not to spill, and wipe up any spills
immediately. Cover parts to avoid damage.

1.

Clean any dirt from the master cylinder cover.

2.

Remove the screws from the cover.

3.

Carefully remove the cover and diaphragm assembly
from the reservoir.

4.

Under the cover, inspect the vent slots under the
bellows and remove any debris or blockage.

5.

Attach a flexible clear hose to the caliper bleeder
screw. Place the other end in a jar or suitable
container.

6.

Have an assistant loosen the bleeder valve one full
turn.

7.

Slowly compress the brake lever. As the brake lever
is depressed to the end of its stroke, the assistant
must retighten the bleeder valve.

8.

Add new brake fluid to the reservoir.

9.

Repeat steps 6 through 9 until new brake fluid flows
out of the clear tube or all of the air bubbles disappear
from the brake fluid.

10. After removing the air or replenishing the brake fluid,

actuate the lever. If the lever feels “spongy”, further
bleeding is required. If the lever feels “stiff”, the
system is fully bled.

11. Torque the bleed fitting when finished.

12. When adding fluid, add DOT 4 brake fluid to 1/4"

(.6cm) from the reservoir top.

13. Install cover and diaphragm assembly.

14. Tighten the cover screws.

15. Field test machine before putting into service. Check

for proper braking action and lever reserve. Lever
reserve is when the lever is firmly applied, the lever
reserve should be no less than 1/2" (1.3 cm) from the
handlebar. 

NOTE:  If the brake lever travel is within specification
and feels “stiff” when the snowmobile is not in
motion, but lever travel increases, or requires more
than one stroke to “pump-up” the brakes when the
snowmobile is in motion, the brake disc may be
warped and requires immediate inspection.

16. Verify that the sight glass indicates a full reservoir. 

17. Check brake system for any fluid leaks.

CAUTION

DO NOT RELEASE THE BRAKE LEVER WHEN THE 

BLEEDER VALVE IS OPEN. DOING SO MAY 

INTRODUCE AIR INTO THE BRAKE HOSE.

T 

Bleeder Screw: 8-11 ft-lb (11-15 N-m)

T 

Cover Screws: 16-20 in-lb (1.8-2.3 N-m)

6.21

Drive and Brake Systems

6

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Brake Hose Replacement

1.

Attach a clear flexible hose to the caliper bleeder
screw. Place the other end of the hose in a jar or
suitable container.

2.

Clean any dirt from the master cylinder cover.
Remove the cover from the master cylinder.

3.

Open the caliper bleeder screw. Actuate the brake
lever and pump the brake fluid into the jar.

4.

Note the orientation and routing of the brake hose.
The brake hose must be replaced following the same
routing and in the same orientation.

5.

Remove the brake hose from the caliper. Cap or cover
the end to catch any brake fluid that may still be in the
line.

6.

Loosen the brake line from the master cylinder 1/4 to
1/2 turn.

7.

Remove the 4 screws that hold the master cylinder to
the handlebar. This will separate the master cylinder
from the switch pack.

8.

Unplug the brake light switch harness from the master
cylinder.

9.

Remove the brake hose from the master cylinder.

10. Install new brake hose on caliper and route/orientate

it as noted in step 4.

11. Torque the caliper banjo bolt to 168-216 in-lb (19-24

N-m).

12. Insert the new brake hose and install into the master

cylinder. Torque the brake line to 144-192 in-lb 
(16-21 N-m).

13. Tighten the brake line into the master cylinder in an

orientation so that the line does not have any sharp
bends when it is installed on the handlebar.

14. Route the brake light switch in the harness correctly.

15. Place the switch pack with the master cylinder onto

the handle bar. Two smaller screws should be placed
on the top and the longest screw is placed on the lower
right.

16. Follow the bleeding procedure. See “Brake Fluid

Replacement & Bleeding” on page 6.20.

Brake Light Switch Replacement

1.

Remove the 4 screws that hold the master cylinder to
the handlebar. This will separate the master cylinder
from the switch pack.

2.

Unplug the brake light switch harness from the master
cylinder.

3.

Unplug the brake light switch from the master cylinder.

4.

Replace faulty brake light switch into the master
cylinder and route wires correctly.

5.

Plug the brake switch back into the harness.

6.

Replace the master cylinder to the switch pack and
insert the smaller screws on the top, the longest one
goes into the lower right side.

144-192 in-lb (16-22\N-m)

brake light switch

168-216in-lb (18.9-24.4 N-m)

T 

Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m)

T 

Brake Line: 144-192 in-lb (16-22 N-m)

6.22

Drive and Brake Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

BRAKE CALIPER

Brake Pad Replacement

NOTE: Always replace both brake
pads at the same time.

The brake pads must be replaced if the
thickness of the friction material is less
than 1/16" (1.6mm).

1.

Rotate and remove the brake pad
retaining pin (3).

2.

Remove the brake pads (4).

3.

Inspect the brake disc (5) for any
wear.

4.

To make room for the new pads,
the pistons must be pushed back into the caliper.

5.

Clean any dirt from the master cylinder cover.
Remove the cover.

6.

Insert two flat blade screwdrivers between one of the
pistons and the brake disc. Evenly pry against the disc
and the piston to push the piston back into the caliper.

7.

Watch the brake fluid level in the master cylinder. The
fluid will rise as the pistons are pushed in. Remove
excess fluid and discard.

8.

Install the new pads and install the new brake pad
retaining pin included with the new pads.

9.

Actuate the brake lever several times to verify proper
operation.

10. Reinstall the master cylinder cover. Clean the caliper

assembly and master cylinder with a clean shop rag.

11. Test the snowmobile at low speed to verify operation.

Caliper Removal / Installation

1.

Rotate and remove the brake pad retaining pin.
Remove both brake pads from the caliper.

2.

Remove the two bolts that secure the caliper to the
chaincase.

3.

Remove the caliper from the brake disc.

4.

To install the caliper, re-mount the caliper around the
brake disc and align the mounting holes.

5.

Install the caliper screws and torque to specification.

Brake Caliper Piston and Seal Replacement

1.

If the caliper is liquid-cooled, drain the cooling system
down enough to drain hoses attached to caliper, or
pinch inlet and outlet hoses.

2.

Remove the brake hose from the caliper. Drain the
brake fluid into a jar or suitable container.

3.

Rotate and remove the brake pad retaining pin and
then remove the brake pads. Remove the caliper from
the chaincase.

1

2

3

4

CALIPER

5

BRAKE DISC

BRAKE PADS

1/16" (1.6mm)

Brake Pad

T 

Caliper Mounting Screws: 18-20 ft-lb (24-27 N-m)

CAUTION

NEVER RE-USE PISTON SEALS. ALWAYS REPLACE 

WITH NEW PARTS.

DO NOT ATTEMPT TO SAND OR POLISH A CALIPER 

PISTON.

PISTONS

PISTON SEAL

PISTON SEAL

CALIPER BORE PLUG
DO NOT PUSH OR MOVE!

6.23

Drive and Brake Systems

6

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

4.

Hold the caliper over the brake fluid jar and then push
the pistons back into the caliper. This will push the
brake fluid in the caliper out of the brake hose banjo
fitting hole.

5.

Clamp the end of a 1/4” thick 2” x 10” piece of steel to
the workbench. Allow the piece of steel to hang off of
the bench by 4 - 5”.

6.

Position the caliper over the steel plate with the plate
firmly against one of the retracted pistons.

7.

Insert a rubber-tipped air nozzle into the brake hose
inlet port and apply compressed air to push out the
piston.

8.

To remove the second piston, lay a rubber sheet on
the steel plate and position the caliper over the rubber
sheet to seal the open piston bore. Repeat STEP 7.

9.

Using a plastic or wood pick, remove both piston seals
from the caliper bores. Discard the seals.

10. Clean the caliper and pistons with denatured alcohol

and dry with either compressed air or a lint-free rag.

11. Inspect the caliper bores and pistons for pitting, heavy

scoring or corrosion. Replace parts if heavily scored
or pitted.

12. To assemble the caliper, lubricate two new piston

seals with new brake fluid. Install each seal by
inserting one point of the seal into the bore groove,
and then work the seal around the groove with your
index finger. Do not twist, or rip the seals.

13. Coat the piston thoroughly with new brake fluid.

Evenly insert each piston into the bores, working each
in by hand carefully and slowly. Push each piston
down until bottomed out.

14. Reinstall the brake caliper on to the chaincase.

Torque fasteners to specification.

15. Inspect both brake pads prior to installation. If they are

within the pad wear specification, reinstall into caliper.

16. Install the brake hose using the same routing and

orientation noted during removal. Torque fitting to
specification.

17. If the caliper is liquid-cooled, reinstall the cooling

hoses. Bleed the cooling system after bleeding the
brake system if required.

18. Fill and bleed the brake system of air. See “Brake

Fluid Replacement & Bleeding” on page 6.20.

19. Test the snowmobile at low speed to verify operation.

Brake Disc Replacement

The brake disc must be replaced if the thickness of the disc
is below .193"(.49cm) or if the disc is warped.

1.

Remove the brake pads from the brake caliper.
Remove the brake caliper from the chaincase.

2.

Do not let the brake caliper hang from the brake hose.
Tie it up to the steering hoop or console.

3.

Remove the chaincase from the bulkhead.

4.

Remove the o-ring from the jackshaft and discard.
Slide the brake disc off of the jackshaft.

5.

Check the jackshaft for any damage.

6.

Replace the o-ring on the jackshaft.

7.

Replace the brake disc. Assemble the chaincase and
re-mount the brake caliper.

CAUTION

DO NOT PUSH ON THE CALIBER BORE PLUG. 

DOING SO WILL BREAK THE PLUG SEAL AND 

REQUIRE CALIPER REPLACEMENT.

WARNING

TO AVOID POSSIBLE INJURY, DO NOT PLACE 

FINGERS BETWEEN PISTONS TO ATTEMPT TO 

CATCH THEM WHEN APPLYING COMPRESSED 

AIR.

WEAR EYE PROTECTION WHEN APPLYING 

COMPRESSED AIR TO CALIPER.

T 

Caliper Mounting Screws: 18-20 ft-lb (24-27 N-m)

T 

Caliper Banjo Bolt: 168-216 in-lb (18-24 N-m)

 

 

 

 

 

 

 

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