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BRAKES
BRAKES
BRAKE SYSTEM SERVICE
NOTES
Polaris disc brake systems are light weight, low
maintenance and perform well in the conditions ATVs
routinely encounter. However, there are a few things
to remember when replacing disc brake pads or
performing brake system service to ensure proper
system function and maximum pad service life.
G
Perform
a
brake
procedure after installing new pads
to maximize service life.
G
Optional pads are available to suit
conditions in your area. Select a pad
to fit riding style and environment.
G
Do not over-fill the master cylinder
fluid reservoir.
G
Make sure the brake lever and pedal
returns freely and completely.
G
Adjust stop pin on front caliper after
pad service.
G
Check and adjust master cylinder
reservoir fluid level after pad service.
G
Make sure atmospheric vent on
reservoir is unobstructed.
G
Test for brake drag after any brake
system service and investigate
cause if brake drag is evident.
G
Make sure caliper moves freely on
guide pins (where applicable).
G
Inspect caliper piston seals for
foreign material that could prevent
caliper pistons from returning freely.
BRAKE NOISE
TROUBLESHOOTING
Dirt or dust buildup on the brake pads and disc is the
most common cause of brake noise (squeal caused
by vibration). If cleaning does not reduce the
occurrence of brake noise, Permatext Disc Brake
Quiet (PN 2872113) can be applied to the back of the
pads. Follow directions on the package. This will
keep pads in contact with caliper piston(s) to reduce
the chance of squeaks caused by dirt or dust.
burnishing
Brake Noise Troubleshooting
Possible Cause
Dirt, dust, or im-
bedded material
with CRC Brake Kleent
on pads or disc
Pad(s) dragging on
disc (noise or
premature pad wear)
Improper adjustment
Insufficient lever or
pedal clearance
Master cylinder res-
ervoir overfilled
Master cylinder
compensating port
restricted
Master cylinder pis-
ton not returning com-
pletely
Caliper piston(s) not
returning
Operator error (riding
the brake / park brake
applied)
Loose wheel hub or
bearings
Brake disc warped or
excessively worn
Brake disc
misaligned or loose
Noise is from other
source (chain, axle,
hub, disc or wheel)
Wrong pad for
conditions
Remedy
Spray disc and pads
or equivalent non-flam-
mable aerosol brake
cleaner. Remove pads
and/or disc hub to clean
imbedded material from
disc or pads.
Adjust pad stop
(front calipers)
Check position of
controls & switches.
Set to proper level
Clean compensating port
Inspect.
Repair as necessary
Clean piston(s) seal
Educate operator
Check wheel and hub
for abnormal
movement.
Replace disc
Inspect and repair as
necessary
If noise does not
change when brake is
applied check other
sources. Inspect and
repair as necessary
Change to a softer or
harder pad
9.3
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