Installation Instructions for Rear Brake Pads for 455cc Diesel EBS (1999-2001 500 Sportsman, 1998-2002 500 Scrambler)

Tools Required:

1. Safety Gear

   • Safety glasses
   • Gloves

2. Basic Tools
   -Socket wrench set
   -Torque wrench

   • Flathead screwdriver
   • Phillips screwdriver

3. Brake Tools

   • Brake caliper tool (or C-clamp)
   • Brake pad spreader

4. Miscellaneous

   • Brake cleaner
   • Rags or shop towels
   • Bungee cord or rope (to hold caliper)

Installation Steps:

1. Prepare the Vehicle

   • Park the vehicle on a flat, stable surface.
   • Engage the parking brake and ensure the vehicle is secure.

2. Remove the Rear Wheel

   • Loosen the lug nuts using the socket wrench.
   • Lift the vehicle using a jack and secure it with jack stands.
   • Remove the slug nuts completely and take off the rear wheel.

3. Access the Brake Caliper

   • Locate the brake caliper and remove the bolts using the socket wrench.
   • Carefully slide the caliper off the rotor. You may need to use a bungee cord or rope to hang the caliper without stressing the brake line.

4. Remove Old Brake Pads

   • Take out the old brake pads from the caliper bracket.
   • Use a flathead screwdriver if necessary to pry them out gently.

5. Compress the Caliper Piston

   • Use a brake caliper tool or a C-clamp to compress the caliper piston back into its housing. This will create enough space for the new pads.

6. Install New Brake Pads

   • Place the new brake pads into the caliper bracket. Ensure they are fitted properly and are secure.

7. Reinstall the Brake Caliper

   • Carefully slide the caliper back over the brake pads and rotor.
   • Tighten the caliper bolts to the manufacturer’s specifications using a torque wrench.

8. Reinstall the Rear Wheel

   • Place the wheel back onto the hub.
   • Hand-tighten the lug nuts and then lower the vehicle back to the ground.

9. Secure the Lug Nuts

   • Once the vehicle is on the ground, use the socket wrench to fully tighten the lug nuts in a crisscross pattern for even distribution.

10. Final Checks

    • Pump the brake pedal several times until you feel resistance to seat the new pads.
    • Check the brake fluid level and add if necessary.

11. Test Drive

    • Take the vehicle for a short test drive to ensure the brakes are functioning properly. Listen for any unusual sounds and check for efficient braking.

Reminder: Always ensure that your work area is clean and free of any hazards. If you are not comfortable performing this installation, seek the assistance of a professional mechanic.