1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 130Get this manual
BRAKE SERVICE Scrambler Output Shaft Caliper Service (Auxiliary Brake) 1234Make alignment marks on stationary ramp and caliper housing as indicated on illustrationRemove cotter key and washer from pedal rod at brake armRemove stationary ramp attaching screws (C) and stationary ramp assembly (D)Remove ramp assemblyIt is not necessary to remove auxiliary brake arm unless brake arm or piston pin are being replacedNOTE: To remove auxiliary brake arm or piston pin, turn the adjuster screw clockwise with 316" Allen wrench until the piston pin falls outTo remove brake arm, insert deep well socket into moveable cam to hold lock nut while backing out the adjuster screwApply downward pressure on brake pads directly over retaining pin, releasing pin pressureShake pin out of caliperNOTE: If pins are corroded it may be necessary to spray penetrating oil on pinsRemove pins and brake padsInsert drift punch in piston pin hole and tap with soft face hammerThis will drive out the caliper pistonSee illustration 3By hand, walk caliper piston back and forth until it can be pulled out of caliperStraighten large paper clip and form small hook on one endPolish the end ofthe clip so there are no sharp edgesCAUTION: Extreme care must be used to avoid scratching the cylinder bore seal ring groove surfacesInsert Drift Punch