Front Caliper Installation - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION
FRONT CALIPER
INSTALLATION
1. Install caliper on hub strut, and torque mounting
bolts.
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm)
2. Install brake line and tighten securely with a line
wrench.
3. Install the adjuster screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
4. Follow brake bleeding procedure outlined on
Pages 9.7-9.8.
5. Install wheels and torque wheel nuts to
specification.
18 ft. lbs.
(25 Nm)
Front Wheel Nut Torque
20 ft. lbs. (27 Nm).
REAR BRAKE PAD REMOVAL
1. Remove caliper mounting bolts and lift caliper off
of disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
NOTE: Brake pads will be free when caliper is
removed from disc.
2. Clean the caliper with brake cleaner or alcohol.
3. Inspect O-Rings in caliper mounting ears.
Replace if necessary.
Measure
Thickness
4. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
9.17