2001 Polaris Sportsman 400-500 DUSE and H.O. Service Manual, Page 309Get this manual
AUXILIARY BRAKE INSPECTION (HYDRAULIC)
Use the following procedure to inspect the auxiliary (foot) brake system and bleed if necessary1First check foot brake effectiveness by applying 50 lb(approx downward force on the pedalThe top of the pedal should be at least (25.4mm) above the surface of the footrest (see Ill1)18 to 14 Free Play 50 lbs or greater
Floorboard Ill1
Free play of the brake pedal should be 1814 inch (3.26.35 mm)If freeplay is excessive, be sure master cylinder piston is returning to the fully extended positionIf freeplay is less than 18 (3.2mm) be sure dust seal is fully seated in groove on master cylinder bodySee photo on page 9.10