Required Tools and Supplies:
- 17mm Socket
- T20 TORX® Socket
- Torque Wrench
- Breaker Bar
- Brake Rotor Measurement Tool
- Brake Pad Measurement Tool
- DOT 4 Brake Fluid
- Tread Depth Gauge
- Tire Pressure Gauge
- Safety Glasses
- Nitrile Gloves
Always wear safety glasses and nitrile gloves when servicing your Polaris ATV. To inspect the wheels and brake system and perform a tire rotation on your model year 2021 and newer Sportsman 450, follow these steps:
1. Take a close look at each tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
- Inspect for damage that may compromise the integrity of the tire.
- Inspect the tire pressure and verify it is set to specification. The tire pressure should be 7 psi (48.3 kPa) for all tires.
- Take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. Inspect the fluid level and condition in the front master cylinder, located on the left handlebar. A flashlight can be used to illuminate the reservoir in dark areas.
3. If fluid is needed, clean the area with a clean cloth.
4. Remove the two cover fasteners with a T20 TORX® socket.
5. Lift the cover and diaphragm off and set aside. Do not allow brake fluid to contact painted surfaces, or paint damage may occur.
6. Add fluid as needed. Do not overfill. A 12-ounce (355 ml) bottle of DOT 4 Brake Fluid is part number 2872189.
7. Reinstall the diaphragm, cover and fasteners. Torque the fasteners to 7 in-lbs (1 Nm).
8. Lift up on the rear of the seat and pull back to remove.
9. Inspect the fluid level and condition in the rear brake reservoir. Add fluid as needed. A flashlight can be used to illuminate the reservoir in dark areas.
10. Reinstall the seat by aligning the front retaining tabs and pushing down in the rear.
11. Begin removing the tires by loosening the lug nuts with a 17mm socket before the vehicle is off the ground. Do not remove.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Remove the lug nuts and set aside.
- Remove the wheels and set aside.
- Follow the front brake lines from the front reservoir to the front junction block in the center of the chassis frame in front of the fuel tank.
- Continue inspecting the brake lines to both front calipers, looking for any leaks, kinks or damage.
- Ensure the brake line retainers are properly secured.
- Inspect the connections at the front brake calipers for leaks or damage.
12. Take a look at the brake pads and rotors. Always allow the brakes to cool completely before inspecting to prevent the risk of burns.
- Check the brake pad thickness using a suitable tool. Be sure to check the thickness on the inside pads as well, and replace any pads that are worn beyond their minimum thickness of 0.180 inches (4.6 mm).
- Use a brake rotor measuring tool to measure the thickness of the brake rotors, and replace if worn below the minimum thickness. The minimum thickness is 0.148 inches (3.76 mm) in the front and 0.178 inches (4.52 mm) in the rear.
13. Follow the brake lines back to the rear of the vehicle, looking for leaks, kinks and damage.
- Inspect the connections at the junction block in the rear of the chassis frame.
- Continue following the brake lines to the rear brake calipers, ensuring the brake line retainers are properly secured.
- Inspect the connections at the rear brake calipers.
14. If inspection reveals any concerns, DO NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
15. The tires can be rotated, if applicable, and reinstalled. Due to different configurations, some wheels may not be able to be rotated. Always pay attention to all markings and directional indicators on the tires.
- Install the wheels on the vehicle and hand-tighten the lug nuts.
- Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torqueing.
- Once lowered, torque the lug nuts to specification in a crisscross pattern. Torque steel wheels to 27 ft-lbs (37 Nm). Torque aluminum wheels to 30 ft-lbs (40 Nm) plus one-quarter turn.
- Lower the vehicle completely.
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.
Neiko® is a registered trademark of Ridgerock Tools, Inc.
Sachs® is a registered trademark of ZF Friedrichshafen AG
TORX® is a registered trademark of Acument Intellectual Properties, LLC