Front Caliper Removal - Polaris SPORTSMAN 600 2003 Service Manual

Brake Disc Thickness
New .150-.164² (3.810-4.166 mm)
Service Limit .140² / 3.556 mm
Brake Disc Thickness Variance
Service Limit: .002² (.051 mm)
difference between measurements.
3. Mount dial indicator as shown to measure disc
runout. Slowly rotate the disc and read total
runout on the dial indicator. Replace the disc if
runout exceeds specifications.
Brake Disc Runout
Service Limit .005² (.127 mm)
FRONT BRAKE DISC
REMOVAL / REPLACEMENT
NOTE: To reduce the possibility of warpage, try
removing the brake disc mounting bolts before
applying heat to the bolts.
1. Apply heat to the hub in the area of the brake disc
mounting bolts to soften the bolt locking agent.
18 ft. lbs. (25 Nm)
new bolts have
pre-applied
locking agent.
9.10
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install disc on hub.
5. Install new bolts and tighten to specified torque.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (25 Nm)
CAUTION: Always use new brake disc mounting
bolts. The bolts have a pre-applied locking agent
which is destroyed upon removal.

FRONT CALIPER REMOVAL

CAUTION:
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if machine
tips or falls.
1. Remove brake pads. See Page 9.9--9.10.
2. Using a line wrench, loosen and remove brake
line to caliper. Place a container under caliper to
catch fluid draining from brake line.
3. Remove brake caliper and drain fluid into
container. Do not reuse brake fluid.
BRAKES BRAKES