Output Shaft Brake Pad Replacement - Polaris 1999 Sportsman 400 Service Manual

BRAKES
NOTE
When the brake sys tem is operating
correctly, the inboa rd and outboard
brake pads should be approxima tely
the same thickness . lfthere is a large
differe nce in pa d wear; the piston
sea ls are faulty and not allo wing the
piston to return properly. This causes
one pad to drag against the disc.
Assem bly
NOTE
Use only lIew, DOT 3 brake
fluid
when
brake f luid is called fo r ill the f ollow-
ing procedure.
1. Install the ble ed va lve int o the bae kside of the
ca liper and tighten securely.
2. App ly brake flu id to the new a -ring sea ls and in-
stall the m into the brake app ly pin bore in the ca li-
per body (Fig ure 35), Make sur e they are properly
sea ted in the grooves.
3. Soak the pi ston seal and dust seal in fresh DOT 3
brake flu id for approx imate ly five m inutes.
4. Lig htly coat the piston and cy linder bore w ith
bra ke flu id.
5. Insta ll a new piston seal into the second groove
in the cy linder bore.
6. Insta ll a new du st sea l into the first gro ov e in the
cy linder bore.
7. Tum the caliper so the bra ke hose fitting threaded
hol e is facin g up. Pour in about 1/4 ounce of bra ke
fluid into the openin g and into the piston bore.
397
NOTE
Check that both se als [it squarely
into their respec tiv e cylinder bore
groO\'es. If a seal is not insta lled
pro pe rly, the calip er assembly will
lea k and braking pe rformance will
be reduced.
8. Positio n the piston with the closed en d go ing in
first and install
the
piston into
the
cylinder bore.
9. App ly high- temperature grease to the brake ap -
ply pin and insta ll the spring and pin into the body
( Fig u re 33).
10. Instal] a new gasket on the body.
I I .
Refer to the marks made in Ste p
3
of
Disassem-
bly. align the
1\1,10
marks and install the stationary
ramp assemb ly onto the caliper body. Insta ll the two
screws (Figure 32) a nd tighten sec urel y.
12. Attach the bra ke hose to the ca lipe r and se-
curel y tighten the
tilting
wit h
a
flare nut wrench .
13. Install the brake pads as described in this ehap-
tel' .
14 . Install the bra ke ca liper assem bly as described
in this chapter.
15. Bleed the brake as described unde r
Bleeding
the Sys tem in
th is chapter.
OUTPUT SHAFT BRAKE PAD
REI'LACEMENT
(199S-0N MO DELS)
There is no recommended interval for changing
the brake pads, Pad wear depend s grea tly on ridi ng
hab its and condi tions. Meas ure the thick nes s of
eac h brake pad w ith a vernier cal iper or ru ler and ,..-...,
com pare
to
the d imens ions listed in Tab le
1.
A lways repla ce both pads in the ca liper at the
same time. Do not disco nnec t the hyd raulic brake
hose from the bra ke ca lipe r for bra ke pad rep lace-
men t, discon nect the hose on ly if the cali per as sem-
bly is goi ng to be remo ved.
I. Remove the scat as de scri bed in Chap ter Fifteen.
2. Remove the fro nt and rear fenders as described
in C hapter Fift een .
3. If
11 0 t
re moved during rear fender removal, re-
mo ve the right -side foo t well.
4. Remove two bo lts, lockwashers and \....ashers
(F igure 36 ) secur ing the brake ca liper
to the tran
s-
mission. Carefully
remove the caliper
up and
off of
the bra ke d isc.