Polaris Outlaw 500, Service Manual, Page: 165 / 202

6.16
BRAKES
Pad Assembly
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (
PN 2871423 ), and
install rubber dust boots.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
3. Install caliper on spindle hub 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.
NOTE: Front Wheel Nut Torque: Refer to Torque
Table at beginning of chapter.
Brake Burnishing Procedure
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
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.
WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads.
Use only new, clean pads.
18 ft. lbs
(24 Nm)
1/2 Turn
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