So, I picked up a machine and the previous owner gave me the plastic bag with the parking brake handle kit still sealed inside. I pulled all of the pieces out and attempted to install it on the handlebars.

If I screw it in tight enough to stay on the machine, it's damn near impossible to move the parking brake lever. If I loosen it enough that I can move the lever, it either doesn't engage or the assembly unscrews itself right off of the mounting position.

What am I doing wrong?

here is a red neck solution, can you grind/shave down the p brake lever just a tad?

What would need to be ground?

There's a washer that goes on the bottom and protrudes through a hole in the Parking Brake lever. The mounting screw goes through that and inserts into the brake bracket. The idea is that the Parking Brake lever should be able to rotate freely on the washer when the screw is tight.

From what I can tell, tightening the mounting screw is pressing the parking brake lever against the brake bracket almost like the washer isn't *quite* tall enough to keep a space between the Parking Brake lever and the brake bracket and it's binding up.

maybe a spacer is missing.,,, If nothing works ,,,get some permanent strength lock tight ,screw it in so it still works and let it set.

Missing spacer / washer is exactly what I was thinking, but there isn't one alluded to in the directions and the bag that it was in was sealed.

The other thing I thought was odd was that the bag contained a screwdriver with a slotted bit, but the mounting screw is Torx.

The exploded diagram in the instructions show a fairly small diameter bushing (the "washer"), but the one included in the kit quite a bit larger in diameter.

Closer inspection of all of the parts seems to indicate that the lever is binding against the bushing. I'm thinking that Polaris changed a part somewhere along the line, and this piece isn't the right piece. I'll have to check with a dealer and see if they have a part lying around.