Front Pad Installation; Brake Burnishing - Polaris 2009 Trail Boss 330 Service Manual

FRONT PAD INSTALLATION

1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install
rubber dust boots.
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).
6. Verify fluid level in reservoir is up to MAX line
inside reservoir and install reservoir cap.
7. Install wheels and torque wheel nuts.

BRAKE BURNISHING

PROCEDURE
It is required that a burnishing procedure be
performed after installation of new brake pads to
18 ft. lbs. extend service life and reduce noise.
(25 Nm)
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.
Master Cylinder Fluid
Up to MAX line inside reservoir
Front Wheel Nut Torque
20 ft. lbs. (27 Nm)
BRAKES
9.11