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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 43

5.14

Final Drive/Brake System

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

BRAKE SYSTEM

General Guidelines

Keep these points in mind when bleeding hydraulic
brakes:

• The master cylinder reservoirs have limited

capacities. It is easy to empty them during the
bleeding procedure. This introduces air into the
system which you are trying to purge. Watch the
reservoir closely and add fluid when necessary to
prevent air from entering the system.

• Apply only light to moderate pressure to the lever

or pedal when bleeding the brake system.
Extreme pressure will cause a surge of fluid
through the small orifices of the brake system
when the bleeder screw is opened and introduce
air into the system by means of cavitation.

• Small amounts of air can become trapped in the

banjo bolt fittings at the master cylinder(s) and
junction points of brake lines. These fittings can be
purged of air by following a standard bleeding
procedure at these fittings (instead of the bleed
screw on caliper) if necessary to speed the
bleeding process. This is usually only needed if
system was completely drained of fluid. Bleed
each line connection, starting with the fitting
closest to the master cylinder, working toward the
caliper, and ending with the bleed screw.

• Always torque banjo bolts and other brake system

fittings to specified torque.

• Change fluid every 2 years, or when fluid is dark or

contamination is suspected.

WARNING

An unsafe condition exists when air is trapped in the

hydraulic brake system. Air in the brake hydraulic

system acts like a soft spring and absorbs a large

percentage of the pressure developed by the master

cylinder. Without this pressure, the braking system

cannot develop full braking force to allow for safe,

controlled stops. It is extremely important to bleed the

brakes properly after any brake system work has been

performed or when inspection reveals spongy brakes.

A soft, spongy feeling in the brake lever and/or brake

pedal could indicate a hazardous condition in the brake

system. Do not operate the vehicle until the failure in

the brake system is corrected.

Keep brake fluid tightly sealed and out of reach of

children. Brake fluid can accumulate moisture,

reducing it's effectiveness.

Contaminated brake discs or brake pads greatly

reduce braking performance and increase stopping

distance. Do not attempt to clean contaminated pads.

Replace them. Clean the brake disc with brake cleaner.

This brake system requires ethylene-glycol based fluid
(DOT 4). Do not use or mix different types of fluid such

as silicone-based or petroleum-based.

Do not use brake fluid taken from old, used or unsealed

containers. Never reuse brake fluid.

CAUTION

Pressure bleeding is not recommended. When fluid

surges through the fittings, it is possible to cavitate the

fluid and create air in the system. In addition, the fluid

stored in a pressure bleeder may be contaminated. Al-

ways use fresh DOT 4 brake fluid from a sealed con-

tainer.

5.15

Final Drive/Brake System

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

Overview

The Polaris snowmobile hydraulic brake system consists
of the following components or assemblies: brake lever,
master cylinder, hydraulic hose, brake caliper (slave
cylinder), brake pads, and a brake disc which is secured
to the drive line.

When the hand activated brake lever (A) is applied, it
contacts a piston (B) within the master cylinder. As the
master cylinder piston moves inward it closes a small
opening called a compensating port (C) within the cylinder
and starts to build pressure within the brake system. As
the pressure within the system is increased, the pistons
(D) located in the brake caliper move toward the disc and
applies pressure to the moveable brake pads. As the lever
pressure is increased, the braking effect is increased.

The friction applied to the brake pads will cause the pads
to wear. As the pads wear, the piston within the caliper self-
adjusts and moves further outward.

Brake fluid level is critical to proper system operation. A
low fluid level allows air to enter the system causing the
brakes to feel spongy.

Compensating Port

Located within the master cylinder is a small
compensating port (C) which is opened and closed by the
master cylinder piston assembly. The port is open when
the brake lever is released and the piston is outward. As
the temperature within the hydraulic system changes, this
port compensates for fluid expansion caused by heat, or
contraction caused by cooling. During system service, be
sure this port is open. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for the brake fluid to expand.
Master cylinder reservoirs should be filled to the top of the

fluid level mark on the inside of the reservoir, 1/4" - 5/16"
(.6 -.8 cm) below lip of reservoir opening.

This system also incorporates a diaphragm (E) as part of
the cover gasket and a vent port (on cover) located
between the gasket and the cover. The combination
diaphragm and vent allow for the air above the fluid to
equalize pressure as the fluid expands or contracts. Be
sure the vent is open and allowed to function. If the
reservoir is overfilled or the diaphragm vent is plugged, the
expanding fluid may build pressure in the brake system
and lead to brake failure.

5.16

Final Drive/Brake System

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

Brake Fluid Replacement & Bleeding

Each hydraulic brake is fitted with a bleeder valve and a
banjo bolt. The bleeder valve is a special screw, which
seals when tightened to the correct torque, but which
allows air and/or fluid to pass out through a hole in the
valve stem when loosened one turn.

NOTE: A second person is usually needed to assist in
bleeding the brakes.

Clean the master cylinder cover and remove.

Attach one end of a flexible tube over the stem of the
bleeder valve.

NOTE: A 'box end' wrench placed on the bleeder
valve before attaching the flexible tubing is a
convenient method for loosening and tightening the
bleed valve.

Place the other end of flexible tube into a jar
containing a small amount of clean fluid. See that the
end of the tube is below the fluid surface to prevent
breathing/sucking air back into the system.

Loosen bleeder valve one turn.

Fully apply the brake and hold, check for air bubbles
rising in the fluid, indicating that air is being forced out
of the system.

Continue actuating the brake until air bubbles stop.
This indicates that the brake has been bled
successfully.

NOTE: Add new fluid to the master cylinder reservoir
as needed.

Retighten the bleeder valve when the brake lever has
reached the end of its stroke. Torque bleeder to
specification.

Evaluate the brake system for proper operation, and
inspect for leaks. The brake lever should feel firm,
without excessive travel and sponginess.

Add new fluid to the master cylinder reservoir to bring
the fluid level back up to a level between the maximum
and minimum fill lines. Replace master cylinder cover.

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

= T

Brake Caliper Bleeder Screws:



Phantom: 100-135 in-lb (11-15Nm)



Phantom Lite: 36-46 in-lb (4-5Nm)

= T

Master Cylinder Cover Screws:



Combined: 16-20 in-lb (1.8-2.3Nm)



Cyclone: 6-8 in-lb (.7-.9Nm)

CAUTION

Caution: Take care not to get brake fluid on pads or disc.

If brake fluid gets on disc, fully clean disc with alcohol.

5.17

Final Drive/Brake System

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

Combined Master Cylinder/Lever Service

Swtich Pack Screw Location/Torque Sequence:

To remove the brake lever, remove the e clip from the
lever pin.

Extract the pin from the housing, then remove the
lever.

To remove the parking brake lever, the housing cover
must be removed. Once removed, carefully extract
the spring noting it its position inside the housing.

Remove the parking brake lever.

To remove the cartridge, completely drain the brake
fluid from the housing. Remove the brake and parking
brake levers.

Disconnect the brake hose from the cartridge.
Carefully pop the cartridge out of the housing.

To install the cartridge, lubricate the entire surface
with DOT 4 brake fluid.

Align the cartridge with the housing tabs, then firmly
press the cartridge back into the housing until the
cartridge is engaged with the tabs.

Refill and bleed the brakes system as outlined in this
chapter. See “Brake Fluid Replacement & Bleeding”
on page 5.16.

Test brake system prior to returning vehicle to service.

Cyclone Master Cylinder/Lever Service

= T

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



Switch Pack Screws: 25-30 in-lb (2.8-3.4Nm)



Brake Hose: 240-264 in-lb (27-30Nm)

COVER SCREWS

COVER

PARKING BRAKE LEVER

CARTRIDGE

BRAKE LEVER

LEVER PIN

E CLIP

SWITCH

#10x.75 SCREWS

#10x1.12 SCREW

#10x1.5 SCREW

TOP

TORQUE SEQUENCE

Torque upper two screws until gap is closed.
Torque bottom two screws to specification.
Test MODE/SET switch for binding.
If switch binds, loosen bottom two screws evenly
until binding stops. Maintain a closed gap at the top.

= T

Cover Screws: 6-8 in-lb (.7-.9Nm)



Handlebar Clamp Screws: 60-80 in-lb (6.8-9Nm)



Brake Hose Banjo Screw: 240-264 in-lb (27-30Nm)

PARKING BRAKE LEVER

BRAKE LEVER

LEVER PIN

COVER

COVER SCREWS

CLAMP

CLAMP SCREWS

BRAKE SWITCH

E CLIP

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