Rear Caliper Removal/Inspection; Rear Brake Pad - Polaris 2004-2005 Sportsman 6x6 Service Manual

Rear Brake Pad Thickness
New .38" (9.65 mm)
Service Limit .170" (4.32 mm)

REAR BRAKE PAD

INSTALLATION
Align pad ears
and caliper
1. Install caliper on brake disc. Start front shoulder
bolt.
2. Insert brake pads on front shoulder bolt. While
holding caliper and pads, align rear mounting pad
lugs with rear shoulder bolt. Install rear shoulder
bolt.
3. Torque mounting bolts to specified torque.
DH Brake Caliper Mounting Bolts Torque:
15 ft. lbs. (21 Nm)
4. Slowly pump the brake levers until pressure has
been built up. Maintain at least 1/2" (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the master cylinder.
Auxiliary Brake Master Cylinder
Fluid Level
Between MIN and MAX lines
9.18
GENERAL INFORMATION
5. It is recommended that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Repeat
procedure 10 times.
REAR CALIPER
REMOVAL/INSPECTION
1. Clean caliper area before removal.
Remove inner
and outer
brake lines
2. Using a flare nut wrench, remove left hand brake
(outer) and right hand brake (inner) lines. Place a
container to catch brake fluid draining from brake
lines.
3. Remove the caliper and pads.
Rear Caliper Piston
Square Rings
4. Remove piston with air pressure to brake line
inlet.
Start
Dust Seal Groove