Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 218 / 289

GENERAL INFORMATION
9.10
Torque both bolts to
25 in.lbs. (3 Nm)
Torque this bolt first
5 in.lbs. (0.56 Nm)
1. Install master cylinder on handlebars. Torque
mounting bolts to 25 in. lbs. (3 Nm). Torque the
inside bolt first as indicated in the illustration to the
right.
NOTE: To speed up the brake bleeding procedure
the master cylinder can be purged of air before brake
line is attached. Fill with DOT3 Brake Fluid ( PN
2870990 ) and pump lever slowly two to three times
with finger over the outlet end to purge master cylinder
of air.
Brake Line
Banjo Bolt
Sealing Washers
Torque to 15 ft.lbs.
(21 Nm)
2. Place new sealing washers on each side of banjo
line and torque banjo bolt to specification.
FRONT PAD REMOVAL
1. Elevate and support front of machine.
CAUTION:
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if machine
tips or falls.
2. Remove the front wheel. Loosen pad adjuster
screw 2-3 turns.
3. Remove caliper from mounting bracket.
4. Push caliper piston into caliper bore slowly using
a C-clamp or locking pliers with pads installed.