Service Notes; Brake Noise Troubleshooting - Polaris Outlaw 500 Service Manual

BRAKES

Service Notes

Disc brake systems are light weight, low 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 conditions in your area. Select a pad to fit riding style and environment
• Do not over-fill the master cylinder fluid reservoirs.
• Make sure the brake levers return freely and completely.
• Check and adjust master cylinder reservoir fluid levels after pad service.
• Make sure atmospheric vent on reservoirs are unobstructed.
• Test for brake drag after any brake system service and investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins.
• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing new pads to maximize service life.
Use only DOT 3 or DOT 4 brake fluid as an assembly aid for all procedures

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, check the backing of each pad for worn spots allowing metal to metal contact. See
table below:
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
6.6
CAUTION
described in this chapter to prevent brake system contamination.
DO NOT USE LUBRICANTS OF ANY KIND FOR ASSEMBLY.
Brake Noise Troubleshooting
Remedy
Spray disc and pads with a non–flammable aerosol brake
cleaner only! 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
RepairPro Service Manual