2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 223Get this manual
BRAKES 5Install brake lines and tighten to specified torqueBrake Disc Thickness Variance Service .002 (.051 mm) Limit difference between measurements 3Mount dial indicator and measure disc runoutReplace the disc if runout exceeds specificationsBrake Disc Runout Service Limit .005 (.127 mm) Auxiliary Brake Line Banjo Bolt Torque 15 ftlbs(21 Nm) 6Follow bleeding procedure outlined on Pages 9.6-9.7 of this section and refer to system overview and illustrations on Pages 9.29.37Field test unit for proper braking action before putting into serviceInspect for fluid leaks and firm brakesMake sure the brake is not dragging when lever is releasedIf the brake drags, re-check assembly and installation
Hand Brake Line
TROUBLESHOOTING
Brakes Squeal Dirtycontaminated friction pads Improper alignment Worn disc Worn disc splines Poor Brake Performance Air in system Water in system (brake fluid contaminated) Caliperdisc misaligned Caliper dirty or damaged Brake line damaged or lining ruptured Worn disc andor friction pads Incorrectly adjusted lever Incorrectly adjusted stationary pad Worn or damaged master cylinder or components Improper clearance between lever and switch Lever Vibration Disc damaged Disc worn (runout or thickness variance exceeds service limit) Caliper Overheats (Brakes Drag) Compensating port plugged Pad clearance set incorrectly Auxiliary brake pedal incorrectly adjusted Brake lever or pedal binding or unable to return fully Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc