1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 136Get this manual
BRAKE SERVICE Output Shaft Brake Caliper Service, 1994 300400L 6x6 1Remove right rear mud flap bolt from footrest2Remove the rear-most middle chain guard bolt (A) and spacer (B)Remove remaining guard bolts (C)Remove middle chain guard (D)Remove upper and lower bolts (E) from disk cover and remove disk cover (F)Rotate brake caliper assembly from o'clock position to 11 o'clock and slide caliper upward to removeApply downward pressure on brake pads directly over retaining pin, releasing pin pressureShake pin out of caliperNOTE: If pins are corroded it may be necessary to spray penetrating oil on pinsRemove pins and brake padsPlace piece of .125" (.3 cm) thick steel plate on stationary side of caliper assembly as if it were the stationary brake padPump master cylinder until piston just makes contact with the plateDo not over apply pressureFluid may leak by piston, buckling steel plate and causing piston to wedge in caliperRemove brake line from caliper assemblyCAUTION: Brake fluid will leak from the lineBe prepared to catch this fluid in shop clothsBrake fluid will damage painted surfacesWipe up any spills at onceProperly