2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 305Get this manual
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely encounterThere are few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life& Optional pads are available to suit conditions in your areaSelect pad to fit riding style and environment& Do not over-fill the master cylinder fluid reservoir& Make sure the brake lever and pedal returns freely and completely& Adjust stop pin on front caliper after pad service& Check and adjust master cylinder reservoir fluid level after pad service& Make sure atmospheric vent on reservoir is unobstructed& Test for brake drag after any brake system service and investigate cause if brake drag is evident& Make sure caliper moves freely on guide pins (where applicable)& Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely& Perform brake burnishing procedure after installing new pads to maximize service life