2005 Polaris Sportsman 400/500 Service Manual, Page 51Get this manual
MAINTENANCE
HOSEFITTING INSPECTION
Check brake system hoses and fittings for cracks, deterioration, abrasion, and leaksTighten any loose fittings and replace any worn or damaged parts
First, check foot brake effectiveness by applying 50 lb(approx downward force on the pedalThe top of the pedal should be at least inch, (25.4mm) above the surface of the footrest18, to 14, Free Play 50 lbs or greater
AUXILIARY BRAKE TESTING
The auxiliary brake should be checked for proper functionAuxiliary Foot Brake Pedal Full Height Full Engagement
Floorboard If less than one inch, two things must be examined: Free Play: Free play of the brake pedal should be 1814 inch (3.26.35 mm)