2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 320Get this manual
BRAKES Overview
Polaris disc brake systems are light weight, low maintenance and perform well in the conditions ATV's routinely encounterHowever, there are few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life Perform brake burnishing procedure after installing new pads to maximize service life Optional pads are available to suit conditions in your areaSelect pad to fit riding style and environment Do not over-fill the master cylinder fluid reservoir Make sure the brake lever and pedal returns freely and completely Adjust stop pin on caliper (if applicable) after pad service Check and adjust master cylinder reservoir fluid level after pad service Make sure atmospheric vent on reservoir is unobstructed Test for brake drag after any brake system service and investigate cause if brake drag is evident Make sure caliper moves freely on guide pins (where applicable) Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely34Rear Brake MC Brake Mount Spring Brake Lever Remove the two bolts that secure the rear master cylinder to the frameReplace parts as neededTo install the rear master cylinder, mount the master cylinder to the frame and torque bolts to specificationFrame Rear Brake Line 2If required, remove the rear brake line from the master cylinderUse suitable container to catch the brake fluidDispose of brake fluid properlyBrake Fluid Reservoir