2004 Polaris Touring Service Manual, Page 274Get this manual
BRAKESFINAL DRIVE Mechanical Brake Disassembly
CAUTION: Whenever inspection reveals worn, damaged or defective parts, replacement is necessary in order to avoid serious damage to the machine or injury to the operator1Open adjuster bolt jam nut locking tab (A)Loosen jam nut and remove adjuster bolt (B)2Remove actuating lever (C) and return springDo not disconnect lever arm from cable3Remove caliper bolts, spacers, bracket nuts (Items 1, 2, 7,8)Remove stationary caliper casting and stationary pad (Items 1011)4Remove top mounting bolts and washers (Items 3, 4,5)Pull outward on disc with the balance of the caliper assemblyOnce disc is free of shaft separate components5Remove brake pads and inspect for wear and damageReplace if necessaryIf stationary pad (Item 11) is stuck to stationary casting, tap on the side of the pad with punch and hammer to break it loose6Inspect rotor disc and replace if necessary
Mechanical Brake Assembly and Installation to Transmission