Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 45

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 45

 

 

5.22

Final Drive/Brake System

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

© 2011 Polaris Sales Inc.

Phantom Lite Brake Caliper Bracket/Seal/

Piston Service

1.

Clean the friction pad area.

2.

Remove the brake caliper from the chain case. Slide 
the caliper off of the brake disc.

3.

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

4.

Remove the two anti-rattle springs. If springs are 
damaged or rusted, discard and replace with new 
springs.

5.

Push the caliper mounting bracket against caliper.

6.

Remove both friction pads.

7.

Extract bracket by pulling it out of caliper. Note spacer 
o-ring on large diameter pin.

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.

SPRINGS

O-RING

5.23

Final Drive/Brake System

5

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

© 2011 Polaris Sales Inc.

8.

Remove the two small and two large o-rings from the 
inside of mounting ears on caliper. Discard the o-
rings. Do not damage the shaft bores when removing 
o-rings.

9.

Thoroughly clean the bracket pins and pin bores with 
brake cleaner.

10. To remove piston, insert a rubber-tipped air nozzle 

into the brake hose inlet port and apply compressed 
air to push out the piston.

11. Using a plastic or wood pick, remove both piston seals 

from the piston bore. Discard both seals.

12. Clean the caliper bore and piston with denatured 

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

13. Inspect the piston and piston bore for pitting, heavy 

scoring or corrosion. Replace parts if damaged.

14. 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.

15. Coat the piston thoroughly with new brake fluid. 

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

16. Install two new small and two new large o-rings into 

the caliper for the bracket pins.

17. Apply a liberal amount of silicone-based grease to the 

bracket pins and pin bores. Install the bracket into the 
caliper.

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

within the pad wear specification, reinstall into caliper. 
Install two new anti-rattle springs.

19. Install the brake hose using the same routing and 

orientation noted during removal. Torque fitting to 
specification.

20. Reinstall brake caliper assembly on chain case. 

Torque fasteners to specification.

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

Fluid Replacement & Bleeding” on page 5.16.

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

WARNING

TO AVOID POSSIBLE INJURY, DO NOT PLACE 

FINGERS BETWEEN PISTON AND CALIPER TO 

ATTEMPT TO CATCH IT WHEN APPLYING 

COMPRESSED AIR.

WEAR EYE PROTECTION WHEN APPLYING 

COMPRESSED AIR TO CALIPER.

T 

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

T 

Brake Caliper Mounting Fasteners:

20-22 ft-lb (27-30 Nm)

5.24

Final Drive/Brake System

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

© 2011 Polaris Sales Inc.

Phantom Lite Brake Pad Replacement

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

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

1.

Clean the friction pad area and 
master cylinder cover.

2.

Remove the two caliper mounting 
mount bolts and slide the caliper 
assembly off the disc. 

3.

Remove master cylinder cover.

4.

Prior to removing old pads from 
caliper, insert a large C-clamp placed on the head of 
the banjo bolt and the backing plate, tighten C-clamp 
carefully until piston is pushed back into the bore, do 
not over tighten, Piston should move easily. If no C-
clamp is available insert a flat blade of large 
screwdriver between pads and pry apart. This action 
should press the caliper piston back into its bore, to 
make room for the new pads. Monitor the master 
cylinder during piston push back and remove any 
excess fluid that is forced back into the reservoir to 
prevent spillage. 

5.

Slide bracket tight to caliper and remove worn friction 
pads and install the new pads making sure that the 
friction material is facing inwards.

6.

Insure slider bores are greased well with silicone-
based grease.

7.

Install bracket into slider bores.

8.

Install new pads making sure that the friction material 
is facing inwards.

9.

Reposition the caliper over the brake disc, insert and 
torque mounting bolts to specification. 

10. With the unit reassembled, actuate the brake lever 

lightly and slowly several times to seat the new pads 
against the disc.

11. Check master cylinder reservoir for proper fluid level 

and replace cover. Torque screws to specification.

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

T 

Brake Caliper Mounting Fasteners:

20-22 ft-lb (27-30Nm)

T 

Master Cylinder Reservoir Screws:

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

1/16(.0625" )/1.5mm

Brake Pad

5.25

Final Drive/Brake System

5

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

© 2011 Polaris Sales Inc.

Brake Disc Replacement

NOTE: Reference Brake Disc Hardware table before 
reinstalling brake disc.

1.

Engage the parking brake. Loosen the brake disc bolt.

2.

Disengage the parking brake.

3.

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

4.

Remove the brake disc bolt, beveled washer and shim 
washer(s) if model is equipped with the phantom 
brake caliper.

5.

Remove the brake disc from the jackshaft.

Brake Disc Service Specifications:

• Lateral Run-Out Service Limit = .010" (.254mm)

• Service Limit Thickness = .030" (.762mm) less 

than nominal

• Nominal Thickness = .197"±.005" (5±.127mm)

6.

Prior to installation, clean brake disc with brake 
cleaner, or denatured alcohol. Dry with compressed 
air or lint-free towel.

7.

Install brake disc on to jackshaft. Reinstall correct 
brake disc hardware.

8.

Reinstall the brake caliper assembly. Torque caliper 
bolts to specification.

9.

Test brake system prior to returning vehicle to service.

10. Lock the parking brake. Torque brake disc bolt to 

specification.

YEAR

/

CALIPER

 

TYPE

BRAKE

 

DISC

 

FASTENER

 

HARDWARE

2010/ 

Phantom

Fastener: 29 ft-lb (40 Nm)

Flat Washer

1-2 Float Washers

(Install QTY. to achieve .8mm Disc Float)

2011-Current/

Phantom

Fastener: 40 ft-lb (54 Nm)

Flat Washer

Wave Washer

1 Float Washer

2011-Current/

Phantom Lite

Fastener: 40 ft-lb (54 Nm)

Domed Washer (Dome facing out.)

T 

Brake Caliper Bolts: 40 ft-lb (54 Nm)

T 

Brake Disc Bolt:

2010: 29 ft-lb (40 Nm)

2011-CURRENT: 40 ft-lb (54 Nm)

 

 

 

 

 

 

 

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