Required Tools and Supplies
- 19mm Socket
- Torque Wrench
- Brake Rotor Measurement Tool
- Brake Pad Measurement Tool
- Breaker Bar
- C-Clamp or Locking Pliers
- Break Cleaner
- All-Purpose 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 inspect and replace the brakes on your Sportsman 450 or 570, follow these steps:
1. Park the vehicle on a flat, level surface and ensure it is in PARK. Set the parking brake.
2. Remove the tires from the vehicle.
a. Begin by loosening the lug nuts with a 19mm socket and breaker bar while the vehicle is on the ground but do not remove at this time.
b. Safely elevate the vehicle. Reference your Owner's Manual for proper lifting techniques.
c. Once safely elevated, remove the lug nuts and set aside.
d. Remove the wheels and set aside.
3. Loosen the set screw on the back of the caliper to allow the caliper mount pin to slide backwards.
4. Remove and retain the two caliper fasteners and four washers.
5. Release the parking brake then carefully remove the caliper from the front hub. Support it with a wire hanger, rope, or tension strap, to avoid kinking or bending the brake line.
6. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers with the pads installed. Brake fluid will be forced back into the master cylinder fluid reservoir, so remove excess fluid as needed to prevent overflow. Note: Clean any spilled brake fluid promptly to prevent paint damage.
7. Compress the caliper mounting pins using the same method.
8. Maneuver the outer brake pad off the mount pin and pivot around the caliper to remove. Repeat this process for the inner brake pad.
9. Disconnect the caliper mount from the caliper boots and slide the caliper mount off the caliper.
10. Before continuing, inspect the two caliper boots for tears or damage and replace if necessary.
11. Clean the mount pins with a shop rag and brake cleaner to remove any old grease or debris.
12. Lubricate the mount pins thoroughly.
13. Continue by inspecting the brake pads for wear or damage and replace if necessary.
14. Install the caliper mount pins into the two caliper boots. There is a lip the boot needs to slide over to be secured. To secure the boots, pinch the boots and twist to work them over the lip of the pins.
15. Compress the caliper mount and mount pins if necessary.
16. Install the inner brake pad onto the mount pin and rotate around the caliper to install on the other pin.
17. Before continuing, very the caliper piston has been compressed sufficiently to install the outer pad. Compress as needed to gain the necessary clearance. Also ensure the caliper mounting pins are sufficiently compressed.
18. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads.
19. Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.
20. Install the washer and spring washer onto the caliper fastener.
21. Align the caliper with the mounting holes on the hub assembly and install the fastener and washers.
22. Torque the fasteners to 23 ft-lbs (31 Nm).
23. Tighten the set screw on the back of the caliper and turn the screw two or three times to engage the patch lock.
24. Repeat this process for the other brake pads as needed. Brake pads on the same axle should be replaced in pairs.
25. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated.
26. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place while you tighten the lug nuts.
27. Once lowered, torque the lug nuts to specification below in a criss-cross pattern.
- Steel wheels: 27 ft-lbs (37 Nm)
- Aluminum wheels: 30 ft-lbs (40 Nm) plus 1/4-turn
28. Safely lower the vehicle completely.
If the brake pads were replaced, the brake burnishing procedure should be completed by slowly bringing the vehicle up to 30 mph 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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