Polaris 1999 Sportsman 400 Service Manual page 392

386
15. Install the inboard bruke pad (F igure II ), then
the outboard brake pad (F igure 12) into the mount-
ing bracket pins.
16. Slowly move the mounting bracket away from
the piston to lock the brake pads in place within the
caliper (Figure 13). Separate the brake pads to al-
low room for the brake disc.
17. Install the caliper onto the brake disc being care-
ful not to damage the leading edge ofthe brake pads.
18. Align the mounting bolt holes with the front
strut and install the bolts. Tighten the bolts (Figure
3) to the torque specification listed in Ta ble 2.
NOTE
To control the flow
0/
hydrau lic fluid,
punch a small hole into the brakefluid
conta ine r sea / next to the edge of the
pOllr
spout.
This
will
help eliminate
jluid spillage especially while adding
f luid to 'he ve l)' small brake
reservoir:
W ARNING
Use brakeJluid clearly ma rk ed DOT 3
f rom a sealed
container:
Other types
may vaporize and
calise brake
[ailur e .
Always use the same brand
lIatlle;
do
110/ intermit as mallY brand'! are not
compatible. Do
110/
Intermi x sili-
cone-based (DO T 5) brake f luid. as it
can ca lise brake co mponent da mage
lea d ing fa brake sys tem failure.
19. Refill the master cylinder reservoir to maintai n
the eorree t lluid level as indicated on the side of the
reservo ir. Install the diaphragm and cover and
tighten the screws securely.
20. With the wheels still off the ground, spin the
wheels and activate the brake lever as many times
as it takes to refill the caliper cylinder and correctly
locate the brake pads against the disc.
21. Install the pad adju st screw and tum it in (Fig-
ure 2) until the outboard brake pad contacts the
brake disc, then back it out 1/2 tum .
22. Install the front wheels as described in Chapter
Twe lve.
WAR NING
Do
1101
ride
the vehicle until it is es -
tabllshed
that the brakes are operat-
ing correctly with
f ull
hydraulic
advantage.
If
I/('cessa /) ; bleed the
brakes as described in this
chapter.
CHAPTER FOU RTEEN
NO TE
17IejiJl/owing instructions apply to orig-
inal equipment-type
pads onty:
If
using
aftermarket brake pads,follow the lIIa11-
ufacturers break-in instructions.
23. Sed the pads in gradually with a burnishing
procedure as follows:
a. Stan the vehicle and slowly increase speed up
to 30 mph (48 kmlh).
b.
Gra dually
apply the brakes and bring the ve-
hiele to a comp lete stop.