Polaris 1999 Sportsman 400 Service Manual page 404

398
5. Release the hoo k POriion o f the retaining pin
(Figure 37) from the ca liper. Do not open the hook
portion any more than necessary, as the pin tension
ma y be lost.
6. Withdraw the retaining pin from thecaliper.
7. Remove the inboard and outbo ard brak e pads
(Figure 38) out through the botto m of the caliper.
8. When repositi oning the brak e pad s in the ca lipe r,
the master cylinder brake fluid level will rise as the
caliper piston is repo siti oned . Perform the follow-
ing:
a. C lean the top of the front ma ster cy linder to
remove all debris.
b. Place a plastic drop clot h ove r the fr ont fender
and fuel tank, under the master cy linder, to
protect them from any accidental brake flu id
spills.
c. Remove the screws securing the top cover
(F igu re 29).
d. Remove the top cove r and diaphragm from
the m aster cy linder.
WARNING
Brake f luid is poisonous ; do not si-
phon it
by
mouth.
9. Carefully push the pistons back into the caliper
cylinders. Constantly check the reservoir to make
sure brake fluid does not overflow. Remove
fluid,
if
necessary,
prior to
it
overflowi ng.
10. Th e pistons should move free ly. If they do not,
remove and service the caliper as described in this
c hapter.
II . Inspect the brake pads (F igure 39) for uneven
wear, damage or grease contamination. Replace the
pads as
a set, if necessary.
12. Mea sure the thick ness of each brake pad with a
ruler or vernier caliper (Fi gu re 40). Rep lace the
brake pad s if the thickn ess of eit her pad is less tha n
the service limit
in Table t.
13. Inspect the brake disc for nicks, corrosion and
radial groove damage. If damaged, remove the
brake disc as descri bed in this chapter.
14. Check the end of each piston for fluid leakage.
If the seals are damaged and/or i f there is fluid leak-
age, overhaul the brake caliper as described in this
chapter.
note
When p urchasing new pa ds, check
with the dealership
10
make sure the
friction compound of the new pad is
CHA PT ER FO URTE EN
compa tible with the disc material. Re-
move any roughnessfrom the hacks of
the new pads with a fi ne-cutfile.
15. Insta ll the inboard brak e pad. then the outboard
brak e pad into the bott om of the ca liper (Fi gure 41 ).
16. Align the brake pad retaining pin holes (A. Fig-
ure 42) with the holes in the ca liper (B, F igure 42)
and
slow ly insert the retaining pin through the cali-
per, out board brake pad , inboard brake pad and the
caliper. Push the retaining pin in until
it stops.