Front Pad Installation - Polaris SPORTSMAN 600 Service Manual

BRAKES
6. Measure the thickness of the pad material.
Replace pads if worn beyond the service limit.
Front Brake Pad Thickness
New .298" / 7.6 mm
Service Limit

FRONT PAD INSTALLATION

1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install
rubber dust boots.
Measure
Thickness
.180" / 4.0 mm
Polaris Premium All Season Grease
(PN 2871423)
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other. Be sure pads and disc
are free of dirt or grease.
3. Install caliper on hub strut, and torque mounting
bolts.
Front Caliper Mounting Bolts
Torque: 18 ft. lbs. (25Nm)
4. Slowly pump the brake lever 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 brake system.
5. Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
18 ft. lbs.
(25 Nm)
9.9