2004 Polaris Touring Service Manual, Page 48Get this manual
MAINTENANCE Brake AdjustmentMechanical Disc Brakes
If excessive brake lever to brake block clearance is evident, the caliper adjuster should be adjusted using the following methodWARNING
Adjust brake with caliper adjuster bolt onlyDo not adjust cable or cable sleeve lengthImproper brake adjustment could result in brake failure which could result in severe injury or death
Caliper Adjustment
1Bend locking tab (A) away from lock nut (B) and loosen lock nut2Push down on actuating lever (C) and insert .015 feeler gauge between the brake disc and outer brake pad3Turn adjusting bolt (D) in until slight pressure is felt against the feeler gauge4While holding adjusting bolt (D), tighten locknut (B)5Bend locking tab (A) against locknutWARNING