2005 Polaris Sportsman 400/500 Service Manual, Page 247Get this manual
FRONT PAD ASSEMBLY
1Lubricate mounting bracket pins with light film of Polaris Premium All Season Grease, and install rubber dust boots
18 ftlbs(24 Nm)
Front Caliper Mounting Bolts Torque: 18 ftlbs(24Nm) 4Slowly pump the brake lever until pressure has been built upMaintain at least 12 (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system5Install the adjuster screw and turn clockwise until stationary pad contacts disc, then back off 12 turn (counterclockwise)