2004 Polaris Sportsman 600/700 Service Manual, Page 236Get this manual
I(I 6Verify flu id level in reservoir is up to MAX line inside raselVoir and install reservoi capNew
Brake Disc Thickness .1SO-.164' (3.810-4.166 mm) Service limit .140' 3.556 mm Brake Disc Thickness Variance Service Limit: .002" (.OS' mm) difference between measurements
Master Cylinder Fluid Up to MAX line inside reservoir
Install wheels and torque wheel nuts3Front Wheel Nut Torque
20 ftIbs(27 Nm)
Mount dial indicator as shown to measure disc runoutSlowly rotate the disc and read totaJ runout on the dial indicatorReplace the disc if runout exceeds specifications
BRAKE BURNISHING PROCEDURE
It is required that burnishing procedure be performed after installation of new brake pads to extend service life and reduce noiseStart machine and slowly increase speed to 30 mphGradually apply brakes to stop machineAl low pads