9.21
BRAKES
9
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
9. Measure the thickness of the pad material. Replace
pads if worn beyond the service limit.
Touring Pad Installation
1. Lubricate mounting bracket pins with a light film of
disc brake caliper lube, and install rubber dust boots.
2. Compress mounting bracket
and make sure dust
boots are fully seated. Install pads with friction
material facing each other.
3. Install caliper and torque the mounting bolts to
specification.
4. Slowly pump the brake lever until pressure has been
b
uilt up. Maintain at least 1/2, (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
5. Install the adjuster screw and turn clockwise until the
station
ary pad contacts the disc, then back off 1/2 turn
(counterclockwise).
6. Verify fluid level in reservoir is up to the MAX line
i
nside reservoir and install reservoir cap.
7. Install wheel(s) and torque wheel nut(s).
8. It is recommended that a burnishing procedure be
p
erformed after installation of new brake pads to
extend service life and reduce noise.
Rear Brake Pad Thickness
Service Limit: .180” (4.6 mm)
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
Caliper Mount Bolt Torque:
18 ft.lbs. (24 Nm)
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