Front Brake Disc - Polaris MS4000 Service And Owner's Manual

BRAKES

FRONT BRAKE DISC

Disc Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2. Use a 0-1" micrometer and measure the disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
Front
Disc
Brake Disc Thickness
New .158" (4.01 mm)
Service Limit .140" (3.56 mm)
Brake Disc Thickness Variance
Service Limit: .002" (.051 mm)
difference between measurements
3. Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specification.
Brake Disc Runout
Service Limit .010" (.254 mm)
9.20
Measure
Thickness
Disc Replacement
1. Remove front brake caliper (see "Front Caliper Service").
2. Remove dust cap, cotter pin, castle nut and washers.
3. Remove the wheel hub assembly from the vehicle and
remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Washers
Nut
4. Clean the wheel hub mating surface and install new disc on
wheel hub. Torque new bolts to 18 ft. lbs. (24 Nm).
60 ft. lbs.
(81 Nm)
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
5. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 60 ft. lbs. (81 Nm) and install a new
cotter pin before installing the dust cap.
6. Install front brake caliper (see "Front Caliper Service").
Follow bleeding procedure outlined earlier in this chapter.
7. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.
Dust
Cap
Cotter
Pin
18 ft. lbs.
(24 Nm)
CAUTION