2004 Polaris Sportsman 600/700 Service Manual, Page 246Get this manual
I(I 5Install brake line and tighten securely with line 2
wrenchTorque the brake lines to the proper
torque specification
Use 0-1" icromete and measure disc thickness at different points around perimeter of discReplace disc if worn beyond service limit
NOTE: See Page 9.3 to identify which style brake
line your ATV has installedDisc
Measure Thickness Brake Disc Thickness
N.w .177.187" (4.496-4.750 mm) Service L.imit .167" (4.242 mm)
Brake Une Torque
Banjo Style: 15ft.lbs(21 Nm) Pipe Fit Style: 12-15 ftIbs(16-20 Nm)Brake Disc Thickness Variance .002" (.051 mm) Service Limit difference between measurements
Follow bleeding procedure outlined on Pages 9.6-9.7 of this section and refer to system