Polaris 1999 Sportsman 400 Service Manual page 405

BRAKES
17. Usc needlenose pliers to install the hook portion
into the caliper hole (F igure 37 ) and make sure it is
hoo ked co rrectly. Do nut open the hook portion any
more than necessary as the pin tension may be lost.
NO TE
To control the sma/lflow
ofhydraulic
fl uid.
p unch a small
hole into
the edge
ofthe brake fluid container seal. This
will help eliminate flu id spillage espe-
cially while adding fluid to the vel}'
small brake
reservoir:
399
18. Install the caliper onto the brake disc. Install the
two bolts, loekwashers and washers (Figure 36) se-
curing the brake caliperto the transmission. Tighten
the bolts to the torque specification listed in Table
2.
WARNING
Use brak efluid clearly marked DO T 3
.I i
mil
a sealed containel: Other
types
may vaporize and ca
lise brak efuilnre.
Always lise the same brand name; do
11 0 1
intermix, as many
brands
are
/101
compatible. Do not interm ix
sill-
cone-based (DO T 5) brakefluid, as it
Cll II
cause brake component damage
leading
10
brake systemfailure.
19. Refill the master cylinder reservoir, if neces-
sary, to maintain the correct fluid level as indicated
on the side of the reservoir. Install the diaphragm
and cover and tighten the screws securely.
20. With the wheels still off the gro und, spin the
right wheel and activate the brake
lever
as
many
times as it takes to refill the caliper cy linders and
correctly locate the brake pads against the disc.
2 1, Install the front and rear fenders as described in
Chapter Fifteen,
22. Install the scat as described in Chapter Fiftee n.
WA RNING
Make
sure that the brakes are operat-
ing correctly with
[ull
hydra ulic ad-
vantag e
before
op erating the
vehicle.
NO TE
The
follo wing'
ins/ru ctions app ly
/0
original equipment tvpe pads only.
If
using aftermarket brake pads, fo llow
the inanufactu rers brea k-in instruc-
tions.
23. Bcd the pads in gradually with a burnishing
procedure as foII0\\l5:
a, Start the vehicle and slowly increase speed up
to 30 mph (48 kill/h).
b. Gradually apply the brakes and bring the ve-
hicle to a complete stop.
c.
Repeat this
proced ure 10
times.
d. For the first 2-3 days of riding, usc only light
pressure as
much
as possible. Immediate
hard
application will glaze the new fri ction pads and
greatly reduce the effectiveness of the brake.
II