Polaris 2005 SPORTSMAN 500 Servise Manual page 247

NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid reservoir
when piston is pushed back into caliper. Remove
excess fluid from reservoir as required.
5. Push mounting bracket inward and slip outer
brake pad past edge. Remove inner pad.
6. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
Measure
Thickness
Front Brake Pad Thickness
New .298"/7.6 mm
Service Limit .180" / 4.6 mm
BRAKES
9.11