Master Cylinder Service; Master Cylinder Removal; Master Cylinder Installation - Polaris General 2020 Service Manual

MASTER CYLINDER SERVICE

MASTER CYLINDER REMOVAL

1. Locate the master cylinder above the left front tire in
the wheel well area.
2. Remove the clip from the clevis pin that attaches the
master cylinder to the brake pedal lever.
3. Place a container to catch brake fluid under the
master cylinder brake line banjo bolts.
IMPORTANT
Brake fluid will damage finished surfaces. Do not allow
brake fluid to come in contact with finished surfaces.
NOTICE
Make note of front and rear brake line locations to
master cylinder.
4. Loosen the brake line banjo bolts and allow fluid to
drain.
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
5. Remove the two mounting fasteners that secure the
master cylinder to the frame.

MASTER CYLINDER INSTALLATION

1. Install the master cylinder into the mounting bracket
on the vehicle. Install mounting fasteners and torque
to specification.
TORQUE
Master Cylinder Mounting Fasteners:
22 lb-ft (30 Nm)
2. Install the brake line banjo bolts in correct location
noted during removal. Torque banjo bolts to
specification.
TORQUE
Brake Line Banjo Bolts:
15 lb-ft (20 Nm)
3. Install the clevis pin and clip holding the master
cylinder to the brake pedal.
4. Check brake pedal free-play. Pedal free-play should
not exceed specification.
Brake Pedal Free-play:
0.090 in (2.28 mm)
5. Bleed the brake system. Refer to "Brake Bleeding /
Fluid Change" page 10.7 procedure.
BRAKE SYSTEM
10
10.47