Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 300 / 406

9.12
BRAKES
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
3. Install caliper on hub strut, and torque mounting bolts.
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. It is required that a
burnishing procedure be performed after installation of new
brake pads to extend service life and reduce noise.
NOTE: Front Wheel Nut Torque: Refer to Chapter 2.
Brake Burnishing Procedure
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 warping may result. Repeat this procedure 10
times.
FRONT BRAKE DISC
Inspection
1. Visually inspect the brake disc for nicks, scratches, or
damage.
WARNING
If pads are contaminated with grease, oil, or liquid
soaked do not use the pads. Use only new clean pads.
18 ft.lbs.
(25 Nm)