Sportsman 400 Ho, 500 Ho, Tractor 500 (Intl.), Forest 500 (Intl.) - Polaris A12MH46AX Service Manual

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Sportsman 400 HO, 500 HO, Tractor 500 (INTL.), Forest 500 (INTL.)

REAR MASTER CYLINDER
COTTER PIN
COTTER PIN
Overview
Polaris disc brake systems are light weight, low
maintenance and perform well in the conditions ATV's
routinely encounter. However, there are a few things to
remember when replacing disc brake pads or performing
brake system service to ensure proper system function
and maximum pad service life.
• Perform a brake burnishing procedure after
installing new pads to maximize service life.
• Optional pads are available to suit conditions in
your area. Select a pad to fit riding style and
environment.
• Do not over-fill the master cylinder fluid reservoir.
• Make sure the brake lever and pedal returns freely
and completely.
• Adjust stop pin on caliper (if applicable) after pad
service.
• Check and adjust master cylinder reservoir fluid
level after pad service.
• Make sure atmospheric vent on reservoir is
unobstructed.
CAP
CLEVIS
BUSHING
FOOT PEDAL
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
CAP
CAP
REAR RESERVOIR
RETURN SPRING
WASHER
• Test for brake drag after any brake system service
and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins
(where applicable).
• Inspect caliper piston seals for foreign material
that could prevent caliper pistons from returning
freely.
Use only DOT-approved brake fluid as an assembly
aid for all procedures described in this chapter to
prevent brake system contamination.
DO NOT USE LUBRICANTS OF ANY KIND FOR
ASSEMBLY, AS THEIR USE CAN CAUSE
RUBBER COMPONENTS TO SWELL.
BRAKES
BRAKE MOUNT PLATE
CAUTION
9
9.31

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