2006 Polaris 120 Owners Manual - Page 64

2006 Polaris 120 Manual

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Maintenance Brake Adjustment ADULT SECTION If excessive brake lever to brake block clearance is evident, the brake cable should be adjusted. If proper adjustment cannot be achieved by using the following methods, check the brake band for excessive wear. Your snowmobile dealer can install a new brake band when necessary. WARNING Improper brake adjustment can result in brake failure, which could result in severe injury or death. Perform the adjustment procedures exactly as outlined or see your Polaris dealer for service. 1. Slide the two rubber protector covers (A) back to expose the cable adjuster. 2. Using an 8mm wrench to hold the barrel nut (B), loosen the jam nut (C) with a 10mm wrench. 3. With your left hand, grasp the cables (D) as close to the adjuster as possible. Use your right hand to rotate the barrel nut until you have reached the proper brake lever adjustment. A D D A C B 4. Check the actuator linkage to ensure there is adequate freedom of movement for positive brake operation and that all floating parts move freely and that all parts are mounted securely. Tighten hardware as required. 1/4-3/8″ (6-10 mm) 5. Tighten the adjuster jam nut and slide the rubber protectors back onto the adjuster. 6. The brake band is adjusted correctly when there's 1/4" - 3/8" (6-10mm) brake lever freeplay and clearance between the brake lever and block with the lever fully E depressed is no more than 3/4" (1.9cm). Torque the band bolt nut (E) to 6 ft. lbs. (8 Nm). 61

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61
ADULT SECTION
Maintenance
Brake Adjustment
If excessive brake lever to brake block clearance is evident, the brake
cable should be adjusted. If proper adjustment cannot be achieved by
using the following methods, check the brake band for excessive wear.
Your snowmobile dealer can install a new brake band when necessary.
WARNING
Improper brake adjustment can result in brake failure, which
could result in severe injury or death. Perform the adjustment
procedures exactly as outlined or see your Polaris dealer for
service.
1.
Slide the two rubber protector covers (A) back to expose the cable
adjuster.
2.
Using an 8mm wrench to hold the barrel nut (B), loosen the jam
nut (C) with a 10mm wrench.
3.
With your left hand, grasp the cables (D) as close to the adjuster as
possible. Use your right hand to rotate the barrel nut until you have
reached the proper brake lever adjustment.
4.
Check the actuator linkage to
ensure there is adequate freedom
of movement for positive brake
operation and that all floating parts
move freely and that all parts are
mounted securely. Tighten
hardware as required.
5.
Tighten the adjuster jam nut and
slide the rubber protectors back
onto the adjuster.
6.
The brake band is adjusted correctly when
there’s 1/4” - 3/8” (6-10mm) brake lever
freeplay and clearance between the brake
lever and block with the lever fully
depressed is no more than 3/4” (1.9cm).
Torque the band bolt nut (E) to 6 ft. lbs.
(8 Nm).
A
A
B
C
D
D
1/4-3/8
″
(6-10 mm)
E