Brake Burnishing Procedure - Polaris SPORTSMAN 400 2003 Service Manual

BRAKES
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 caliper mounting bolts and lift caliper off
of disc.
NOTE: When removing caliper, be careful not to
damage brake line. Support caliper so as not to kink
or bend brake line.
3. Push caliper pistons into caliper bore slowly with
pads installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid reservoir
when piston is pushed back into caliper. Remove
excess fluid from reservoir as required.
4. Remove the clip from the slide bolt.
5. Remove a slide bolt with a hex wrench.
6. Remove the brake pads from the caliper.
7. Clean the caliper with brake cleaner or alcohol.
Clip
Remove
Brake Pads
9.17