Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 220 / 289

GENERAL INFORMATION
9.12
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.
18 ft. lbs.
(25 Nm)
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.
Master Cylinder Fluid
Up to MAX line inside reservoir