Polaris SPORTSMAN 600 2003 Service Manual page 220

REAR BRAKE PAD REMOVAL CONT'D
8. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
Measure
Thickness
Rear Brake Pad Thickness
New: .318² (8.0 mm)
Service Limit:
REAR BRAKE PAD
INSTALLATION
1. Install new brake pads in caliper body.
Install Pads
2. Tighten the slide pin with a hex wrench.
3. Install the slide bolt snap ring. Torque the slide pin
to 30--35 ft. lbs. (41 Nm--48 Nm).
Caliper Slide Pin Torque:
30- -35 ft. lbs. (41 Nm- -48 Nm)
9.16
.180² (4.6 mm)
Torque
Slide Pin
4. Install caliper and torque the mounting bolts.
Torque Mounting
Bolts
Rear Brake Caliper
Torque: 18 ft. lbs. (25 Nm)
5. Slowly pump the brake lever until pressure has
been built up. Maintain at least 1/2² (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the master cylinder.
6. 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.
BRAKES BRAKES
Start