Required Tools and Supplies:
- Shop Rags
- Brake Rotor Measurement Tool
- Brake Pad Measurement Tool
- Tire Pressure Gauge
- Brake Fluid
- T20 TORX® Socket
- Tread Depth Gauge
- 17mm Socket
- Torque Wrench
- Breaker Bar
- Safety Glasses
- Nitrile Gloves
Always wear safety glasses and nitrile gloves when servicing your Polaris Sportsman. To inspect the wheels and brake system and perform a tire rotation on your Sportsman 850 High Lifter Edition or Sportsman XP 1000 High Lifter Edition, 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 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.
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 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. Remove the tires by loosening the lug nuts with a 17mm socket before the vehicle is off the ground, but 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.
- 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.
9. 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 micrometer to measure the thickness of the brake rotors. Replace if worn below the minimum thickness of 0.167 inches (4.24 mm).
10. Next, 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.
- Also inspect the connections at the rear brake calipers.
11. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
12. 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.
- Torque the lug nuts to specification in a crisscross pattern. Torque aluminum wheels to 75 ft-lbs (102 Nm). Torque steel wheels to 45 ft-lbs (61 Nm).
- 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.
TORX® is a registered trademark of Acument Intellectual Properties, LLC