Polaris 2012 Sportsman Forest 500 International, Service Manual

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9.15
BRAKES
9
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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.
2. Measure the disc thickness at eight different points
around the pad contact surface. Replace disc if worn
beyond service limit.
18 ft.lbs.
(25 Nm)
= In. / mm.
Brake Disc Thickness:
Service Limit: .140” / 3.556 mm
= In. / mm.
Brake Disc Thickness Variance Service Limit:
.002” (.051 mm) between measurements.