Front Disc Inspection - Polaris Sportsman 400 Service Manual

BRAKES
FRONT PAD ASSEMBLY, CONT.
7. Install wheels and torque wheel nuts.
8. It is recommended that a burnishing procedure be
performed after installation of new brake pads to extend
service life and reduce noise. Start machine and slowly
increase speed to 30 mph. Gradually apply brakes to
stop machine. Repeat procedure 10 times.
Front Wheel Nut Torque
20 ft. lbs. (27 Nm)

FRONT DISC INSPECTION

1. Visually inspect the brake disc for nicks,
scratches, or damage.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0-1"
micrometer. Replace disc if worn beyond service
limit.
Brake Disc Thickness
New .150-.164" (3.810-4.166 mm)
Service Limit .140" / 3.556 mm
Brake Disc Thickness Variance
Service Limit .002" (.051 mm)
difference between measurements.
3. Mount dial indicator as shown to measure disc
runout. Slowly rotate the disc and read total
runout on the dial indicator. Replace the disc if
runout exceeds specifications.
Brake Disc Runout
Service Limit .005" (.127 mm)
9.16
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