Hello fellows has anybody else had trouble changeing the brake shoes on the sportsman 500 well I got them off no trouble at all. But the way they are designed the new shoes don't want to go on unless I bend them or pry them...are they something I am missing here...thanks...BiLL

 

You have to push the piston back into the caliper. It comes out the more you pads wear down and when you put new pads on you have to push it back to "home" postion.

 

I did that Chopper with a c clamp where I am having trouble is getting the shoes to go back on the posts the piece in the middle that looks like an upside down c is keeping me from getting them back on...

 

I don't know for sure if the sportsman calipers are the same as mine, but on my polaris you have to remove one allen set screw located behind one of the pins. the pin can slide back allowing the pads to come off. Or if you slightly bend the pad, it will come off/ go on easy. But I don't suggest doing that!

 

92LT, you are correct in your thinking, my 2000 SP 500 has the elusive allen screw on the back side, but it is still a pain in the neck to get them on. The back pads are much easier to replace.

Does everyone wear them out as fast as I do? I get 2-3 30 mile rides out of a set of pads, but we do ride in mud, sand and water.........

 

Hey Bill, is it possible you’re trying to put “shoes” on a machine that has pads? (sorry, you left yourself wide open for that one) A large channel-lock pliers easily retracts the caliper piston. Like the others here I back the set screw off to get the new pads in, then readjust. Just pretend you’re Houdini, you’ll get’em in there.

 

ATVing,
actually,im guessing that its the front pads only that are giving you trouble?Whats happening is you are NOT sliding the caliper [I dont mean the piston] guide back completely to allow the pads to set into the caliper correctly.Dont BEND ANYTHING.The piston must be shoved in all the way,I know you know that,than make sure the caliper is pushed all the way back on its guide pins,this will allow easy access for you to slide the pads into the caliper.Whats happening is your NOT allowing the caliper to go COMPLETELY back on the guide pins and its leaving you very little room to slide in the pads,also,make SURE that the caliper SLIDES real nicely back and forth on the pins before installing the caliper onto the rotor,
Bill

 

Isn’t it wonderful how Polaris ownership just about automatically turns you into a brake mechanic. Polaris should put explicit instructions for brake pad replacement in the owners manual. Ahhh the owners manual, I don’t even want to get started talking about that worthless piece of $hit.

 

hhhhhh he said shoes Butthead you got me on that one floodrunner hehehe...thanks for the advice fellows soon as it warms up I am going to give it another try I am pretty sure the piston is back as far as it goes but I haven't playes with the hex key adjustment yet...thanks fellow...BiLL