Front Pad Assembly - Polaris SPORTSMAN 400 2003 Service Manual

BRAKES
Front Brake Pad Thickness
New .298²/7.6 mm
Service Limit .180² / 4.0 mm

FRONT PAD ASSEMBLY

1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install
rubber dust boots.
Measure
Thickness
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 1/2² (12.7 mm) of
brake fluid in the reservoir to prevent air from
entering the brake system.
18 ft. lbs. (25 Nm)
9.11