2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 214Get this manual
BRAKES Brake Disc Thickness New .150-.164 (3.810-4.166 mm) Service Limit .1403.556 mm Brake Disc Thickness Variance Service Limit: .002 (.051 mm) difference between measurements3Mount dial indicator as shown to measure disc runoutSlowly rotate the disc and read total runout on the dial indicatorReplace the disc if runout exceeds specifications2345Remove bolts and discClean mating surface of disc and hubInstall disc on hubInstall new bolts and tighten to specified torqueFront Brake Disc Mounting Bolt Torque 18 ftlbs(25 Nm) CAUTION: Always use new brake disc mounting boltsThe bolts have pre-applied locking agent which is destroyed upon removal
FRONT CALIPER REMOVAL
CAUTION:
Use care when supporting vehicle so that it does not tip or fallSevere injury may occur if machine tips or falls1Remove brake padsSee Page 9.99.102Using line wrench, loosen and remove brake line to caliperPlace container under caliper to catch fluid draining from brake lineBrake Disc Runout Service Limit .005 (.127 mm)