Indy Project Sled - Liquid-Cooled Brake Kit

Nov. 01, 2005 By ORC STAFF

Liquid-cooled brake kit

Cost: Under $100 (US)
Risks: Minor
Benefits: Reduced brake-fade during hard running
Tools Required: Sockets, wrenches, other basic tools
Parts Required: Liquid-cooled brake kit from Polaris
Mechanical Skill Required: Average "shade-tree" mechanical skills

This dandy little kit is available from Polaris. It consists of a small, hollow aluminum channel that fits in the caliper behind the inboard brake pad through which engine coolant flows and all necessary hoses and clamps. To install it, you must remove the caliper - gotta remove the jackshaft to do this, so try to consolidate all these mods into one project. The liquid-cooled brake kit is cheap and easy to put on, so if you are going to have the jackshaft off for some other reason, it's a nice little add-on to throw in at the same time.

Once the caliper is out, dismantle it by removing the two bolts that hold it together. Separate all the pieces and reassemble using the new, wider bracket and insert the coolant channel between the caliper and the inboard pad. Bolt the caliper back together and reinstall the brake and jackshaft. The final step is to re-route the coolant hoses from the engine to the chaincase-side running board cooler.

I have heard varying opinions about the liquid-cooled brakes on Polaris sleds. No other manufacturer has this feature and I heard an Arctic Cat engineer comment that they don't feel the brake gets hot enough under any conditions, including racing, to warrant the extra plumbing. But there's a reason Polaris puts it on their high performance sleds, it may only be for mental horsepower reasons, but I no longer worry about overheating my brake even on the twistiest technical section of trail.

It's an easy (if you're already removing the jackshaft for some other reason), inexpensive mod that I highly recommend for all older Polarii. Newsletter
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