Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 44

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 44

 

 

5.18

Final Drive/Brake System

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

Brake Line Replacement

Follow these steps if the brake line is to be replaced.

1.

Drain the brake system by attaching a clear hose to 
the caliper bleed fitting.

2.

Attach the other end to a Mity Vac or similar vacuum 
tool.

3.

Bleed the system of brake fluid.

4.

Note the orientation of the brake line. The brake line 
will need to be replaced in the same orientation. 
Remove the brake line from the caliper assembly. Use 
a shop towel to catch any remaining brake fluid in the 
hose.

5.

On Cyclone master cylinders, remove the banjo bolt, 
washers and fitting from reservoir.

6.

On combined master cylinder, 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 line from the master cylinder.

10. Install new brake line on caliper and orientate it as 

noted in step 4.

11. Insert the new brake line and install into the master 

cylinder. Torque the brake line to specification.

12. 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.

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

BRAKE SWITCH

BRAKE HOSE FITTING

COMBINED MASTER CYLINDER SHOWN

T 

Brake Caliper Banjo Bolt:

240-264 in-lb (27-30Nm)

T 

Brake Line-to-Master Cylinder:

 240-264 in-lb (27-30Nm)

5.19

Final Drive/Brake System

5

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

14. On combined master cylinders, 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.

15. Follow the bleeding procedure. See “Brake Fluid 

Replacement & Bleeding” on page 5.16.

16. Test brake system prior to returning vehicle to service.

Brake Hose Routing

Route brake hose over steering block, under right over 
structure tube, and behind coolant surge tank.

Combined MC 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.

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

4.

Plug the brake switch back into the harness.

5.

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.

Phantom Brake Caliper Removal

1.

Remove the two caliper bolts that hold the caliper and 
silencer bracket to the chaincase.

NOTE: DC-CFI-2 models with Phantom calipers do 
not feature silencer bracket. Washers are installed in 
its place.

CAUTION

Do not pinch brake hose between over structure tubes 

and steering block or between hood and hood mounts.

SILENCER BRACKET
600 RUSH DC-CFI-4 MODELS ONLY
ALL OTHER PHANTOM=WASHERS

5.20

Final Drive/Brake System

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

2.

Remove the caliper from the chaincase. Tie the 
caliper to the overstructure. Do not allow the brake 
caliper to hang from the brake hose.

Phantom Brake Caliper Installation

1.

Apply Loctite® 242™ and replace caliper bolts, and 
silencer bracket or washers if equipped. Torque bolts 
to specification.

2.

Place the brake line on the caliper in the same 
orientation as it was before it was removed.

3.

Clean the threads of the banjo bolt and the threads in 
the caliper.

4.

Follow Brake Line Replacement. See “Brake Line 
Replacement” on page 5.18.

5.

Install banjo bolt into the caliper and torque it to 
specification.

6.

Bleed the brakes. See “Brake Fluid Replacement & 
Bleeding” on page 5.16.

7.

Test brake system prior to returning vehicle to service.

Phantom Brake Caliper Piston and Seal 

Replacement

1.

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

2.

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

3.

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.

4.

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”.

T 

Caliper Bolts: 40 ft-lb (54 Nm)

CAUTION

NEVER RE-USE PISTON SEALS. ALWAYS REPLACE 

WITH NEW PARTS.

DO NOT ATTEMPT TO SAND OR POLISH A CALIPER 

PISTON.

CAUTION

NEVER RE-USE BRAKE FLUID. USED BRAKE FLUID 

MAY CONTAIN AIR BUBBLES. ALWAYS USE NEW 

BRAKE FLUID FROM A UNOPENED CONTAINER.

PISTONS

PISTON SEAL

PISTON SEAL

CALIPER BORE PLUG
DO NOT PUSH OR MOVE!

5.21

Final Drive/Brake System

5

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

5.

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

6.

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

7.

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.

8.

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

9.

Clean the caliper and pistons with denatured alcohol 
and dry with either compressed air or a lint-free rag.

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

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

11. 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.

12. 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.

13. Reinstall the brake caliper on to the chaincase. 

Torque fasteners to specification.

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

within the pad wear specification, reinstall into caliper.

15. Install the brake hose using the same routing and 

orientation noted during removal. Torque fitting to 
specification.

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

Fluid Replacement & Bleeding” on page 5.16.

17. Test brake system prior to returning vehicle to service.

Phantom Brake Pad 

Replacement

Brake pads need to be replaced if the 
thickness of the friction material is less 
than 1/16" (.0625") / 1.5mm.

1.

Remove brake pad retaining pin.

2.

Remove the brake pads.

3.

Inspect the brake disc for any wear. 

4.

Replace brake pads in reverse 
order of removal.

5.

Test brake system prior to returning 
vehicle to service.

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 Nm)

T 

Caliper Banjo Bolt: 240-264 in-lb (27-30Nm)

1/16(.0625") / 1.5mm

Brake Pad

 

 

 

 

 

 

 

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