Rear Brake Disc; Disc Inspection - Polaris Outlaw 500 Service Manual

BRAKES
3. Torque the caliper slide bolts to 33 ft.lbs. (45 Nm).
4. Install the caliper mounting bolts and torque both bolts to
18 ft. lbs. (24 Nm).
5. Install the c-clips (C) onto the ends of the caliper slide bolts.
6. Slowly pump the brake levers until pressure has been built
up. Maintain at least 1/2" (12.7 mm) of brake fluid in the
reservoir to prevent air from entering the master cylinder.
Auxiliary Brake Master Cylinder
Fluid Level
Between MIN and MAX lines
6.22
33 ft.-lb.
(45Nm)
18 ft. lbs. (24 Nm)
C
NOTE: BRAKE BURNISHING: It is recommended
that a burnishing procedure be performed after
installation of new brake pads to extend service life
and reduce noise. Start machine and slowly increase
speed to 30 mph. Gradually apply brakes to stop
machine. Repeat this procedure 10 times, allowing
brakes to cool sufficiently after each run.

REAR BRAKE DISC

Disc Inspection

1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
Rear Brake
Disc
2. Use a 0–1" micrometer and measure disc thickness at 8
different points around perimeter of disc. Replace disc if
worn beyond service limit.
Brake Disc Thickness
New: .158" (4.013 mm)
Service Limit: .140" / 3.556 mm
Brake Disc Thickness Variance
Service Limit: .002" (.051 mm)
(difference between measurements)
3. Mount dial indicator and measure disc runout. Replace the
disc if runout exceeds specifications.
Brake Disc Runout
Service Limit: .010" (.25 mm)
Measure
Thickness
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