Polaris 2005 SPORTSMAN 500 Servise Manual page 253

BRAKE BURNISHING
PROCEDURE
It is required that a burnishing procedure be
performed after installation of new brake pads to
extend service life and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads
and disc to cool sufficiently during the procedure. Do
not allow pads or disc to become hot or warpage may
result. Repeat this procedure 10 times.
REAR BRAKE PAD REMOVAL
1. Support the machine. Remove the rear tire.
2. Remove one of the slide pin clips from the slide
bolt.
3. Loosen one of the slide pins with a hex wrench.
4. Remove caliper mounting bolts and lift caliper off
of disc.
NOTE:
damage brake line. Support caliper so as not to kink
or bend brake line.
5. Push caliper pistons into caliper bore slowly with
pads installed.
NOTE:
compensating port into master cylinder fluid reservoir
when piston is pushed back into caliper. Remove
excess fluid from reservoir as required.
6. Remove the caliper slide pin and remove the
Clip
brake pads from the caliper.
7. Clean the caliper with brake cleaner or alcohol.
8. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
When removing caliper, be careful not to
Brake fluid will be forced through
Remove
Brake Pads
BRAKES
9.17