Disc Brakes; Brake Service - Polaris 1999 Sportsman 400 Service Manual

CHAPTER FOURTEEN
BRAKES
This chapter describes service procedures for the
front brake s and the output shaft brake. Tab le I and
Table 2 are located at the end o f this chap ter.
DISC BRAKES
There are two types of brake systems used on the
various models.
On 1996-1997 models, the front master cylinder
cont rols the front disc brakes and the output shaft
brake. The rear pedal controlsthe outputshaft brake
via mechanical means.
On 1998-on models, the front master cylinder
contro ls the front disc brake and the dual-hydraulic
o utput shaft brake. The rear master cy linder also
controls the dual-h ydrau lic outp ut shall brake. The
output shaft brak e caliper can be con trolled by ei-
ther or both master cylinders.
Brake Service
The disc brake system transmits hydraulic pres-
sure from the mastercylinders to the brake calipers.
This pressure is transmitted from the ealiper(s) to
the brake pads, which grip both sides of the brake
d isc(s) and slow the ATY. As the pads wear, the pis-
tons
move out of the ca liper bores to automatica lly
co mpensate for wear. As this occ urs, the fluid leve l
in the reservoir goes down. This must be compen-
sated for by occasionally addi ng fluid.
The proper opera tion of this system depends on a
supply of clean brake fluid (DOT 3) and a clea n