Required Tools and Supplies
- 13mm Socket
- 17mm Socket
- 5mm Allen Socket
- Torque Wrench
- Breaker Bar
- C-Clamp or Locking Pliers
- Wire Hanger, Rope, or Tension Strap
- Brake Cleaner
- High Temperature Grease
- Safety Glasses
- Nitrile Gloves
- Shop Towels
To learn more about tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris ATV.
To replace the front brake pads on your Sportsman 450 or 570, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK, and set the parking brake.
2. Using a 17mm socket with breaker bar, loosen the lug nuts while the vehicle is on the ground but do not remove at this time.
3. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
4. Once safely elevated, remove the lug nuts and set aside.
5. Remove the wheel and set aside.
6. Loosen the set screw on the back of the caliper with a 5mm Allen socket to allow the caliper mount pin to slide backwards.
7. Remove and retain the two caliper fasteners and four washers with a 13mm socket.
8. Continue by releasing the parking brake.
9. Carefully remove the caliper from the hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.
10. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers with the pads installed, until the piston does not move. Brake fluid will be forced back into the master cylinder fluid reservoir. Remove excess fluid as needed to prevent overflow. Also remember to clean up any brake fluid promptly to prevent paint damage.
11. Compress the caliper mounting pins using the same method.
12. Using a C-clamp or locking pliers, continue by maneuvering the outer brake pad off the mount pin and pivoting around the caliper to remove.
13. Repeat this process for the inner brake pad.
14. Disconnect the caliper mount from the caliper boots and slide the caliper mount off the caliper.
15. Before continuing, inspect the two caliper boots for tears or damage and replace as necessary.
16. Clean the mount pins with a shop rag and brake cleaner to remove any old grease or debris.
17. Lubricate the mount pins thoroughly with high temperature grease.
18. Continue by inspecting the brake pads for wear or damage and replace if necessary. Also replace if worn to their minimum thickness of 0.180 in (4.6 mm).
19. Install the caliper mount pins into the two caliper boots. There is a lip that the boots need to slip over to be secured. To do this, pinch the boots and twist to work them over the lip on the pins.
20. Install the inner brake pad onto the mount pin and rotate around the caliper to install on the other pin.
21. Before continuing, verify that the caliper piston has been compressed sufficiently to install the outer pad. Compress as needed with a C-clamp or locking pliers to gain the necessary clearance. Also ensure that the caliper mounting pins are sufficiently compressed.
22. Carefully slide the caliper assembly onto the brake disc ensuring the brake rotor is between the two pads. Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.
23. Install the spring washer and washer onto the caliper fasteners.
24. Continue by aligning the caliper with the mounting holes on the hub assembly and install the fastener and washers.
25. Torque the fasteners to 18 ft-lbs (24 Nm).
26. Tighten the set screw on the back side of the caliper and turn the screw until the pads touch the brake disc.
27. Loosen the set screw a half turn to allow the brake disc to move.
28. Continue by repeating this process for the remaining brake pads as needed. Brake pads should be replaced in pairs on the same axle.
29. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
30. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
31. Once lowered, torque the lug nuts to specification in a crisscross pattern.
- Steel: 27 ft-lbs (37 Nm)
- Aluminum: 30 ft-lbs (40 Nm) plus 1/4 turn
32. Safely lower the vehicle completely.
33. If the pads were replaced, the brake burnishing procedure should be completed by slowly bringing the vehicle up to 30 miles per hour and gradually applying the brakes until stopped. Repeat this procedure 10 times while ensuring the brakes have had sufficient time to cool between runs to prevent brake disc warping.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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