Special Tools; Brake System Service Notes; Brake Noise Troubleshooting - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION

SPECIAL TOOLS

PART NUMBER
2870975
BRAKE SYSTEM SERVICE
NOTES
Disc brake systems
maintenance, and perform well in the conditions ATVs
routinely encounter. 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.
Optional pads are available to suit
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conditions in your area. Select a pad to fit
riding style and environment.
Do not over-fill the master cylinder fluid
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reservoirs.
Make sure the brake levers return freely
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and completely.
Adjust stop pin on front caliper after pad
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service.
Check and adjust
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reservoir fluid levels after pad service.
Make sure atmospheric vent on reservoirs
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are unobstructed.
Possible Cause
Dirt, dust, or imbedded material on pads or disc
Pad(s) dragging on disc (noise or premature pad wear)
Improper adjustment
Insufficient lever or pedal clearance
Master cylinder reservoir overfilled
Master cylinder compensating port restricted
Master cylinder piston not returning completely
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
TOOL
DESCRIPTION
Mity Vact
Pressure Test Tool
are light weight, low
master cylinder

Brake Noise Troubleshooting

Test for brake drag after any brake system
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service and investigate cause if brake
drag is evident.
Make sure caliper moves freely on guide
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pins.
Inspect caliper piston seals for foreign
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material that could prevent caliper pistons
from returning freely.
Perform a brake burnishing procedure
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after installing new pads to maximize
service life.
CAUTION:
Use only DOT 3 brake fluid as an
assembly aid for all procedures described in this chapter to
prevent brake system contamination. DO NOT USE
LUBRICANTS OF ANY KIND FOR ASSEMBLY.
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.
contact with caliper piston(s) to reduce the chance of
squeaks caused by dirt or dust. See table below.
Remedy
Spray disc and pads with CRC Brakeleent or an
equivalent non-flammable aerosol brake cleaner. Re-
move 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
This will keep pads in
9.3