9.31
BRAKES
9
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Sportsman 400 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.)
Overview
Polaris disc brake systems are light weight, low
maintenance and perform well in the conditions ATV’s
routinely encounter. However, there are a few things to
remember when replacing disc brake pads or performing
brake system service to ensure proper system function
and maximum pad service life.
• Perform a brake burnishing procedure after
inst
alling new pads to maximize service life.
• Optional pads are available to suit conditions in
y
our area. Select a pad to fit riding style and
environment.
• Do not over-fill the master c
ylinder fluid reservoir.
• Make sure the brake lever and pedal returns freely
and completely
.
• Adjust stop pin on caliper (if applicable) after pad
se
rvice.
• Check and adjust master cylinder reservoir fluid
level af
ter pad service.
• Make sure atmospheric vent on reservoir is
uno
bstructed.
• Test for brake drag after any brake system service
an
d investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins
(wh
ere applicable).
• Inspect caliper piston seals for foreign material
that
could prevent caliper pistons from returning
freely.
BRAKE MOUNT PLATE
FOOT PEDAL
REAR MASTER CYLINDER
REAR RESERVOIR
RETURN SPRING
WASHER
COTTER PIN
BUSHING
CAP
CAP
CAP
COTTER PIN
CLEVIS
Use only DOT-approved brake fluid as an assembly
aid for all procedures described in this chapter to
prevent brake system contamination.
DO NOT USE LUBRICANTS OF ANY KIND FOR
ASSEMBLY, AS THEIR USE CAN CAUSE
RUBBER COMPONENTS TO SWELL.
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