Troubleshooting - Polaris SPORTSMAN 600 2003 Service Manual

BRAKES BRAKES
5. Install brake lines and tighten to specified torque.
Hand Brake
Line
Banjo Bolt Torque
15 ft. lbs. (21 Nm)
6. Follow bleeding procedure outlined on Pages
9.6-9.7 of this section and refer to system
overview and illustrations on Pages 9.2--9.3.
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 lever is released.
re-check assembly and installation.
REAR BRAKE DISC
INSPECTION
1. Visually inspect disc for scoring, scratches, or
gouges. Replace the disc if any deep scratches
are evident.
2. Use a 0-1² micrometer and measure disc
thickness at 8 different points around perimeter of
disc. Replace disc if worn beyond service limit.
Rear Brake
Disc
Brake Disc Thickness
New .177-.187² (4.496-4.750 mm)
Service Limit .167² (4.242 mm)
Auxiliary
Brake Line
If the brake drags,
Measure
Thickness
Brake Disc Thickness Variance
Service Limit .002² (.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 .005² (.127 mm)

TROUBLESHOOTING

Brakes Squeal
G Dirty/contaminated friction pads
G Improper alignment
G Worn disc
G Worn disc splines
Poor Brake Performance
G Air in system
G Water in system (brake fluid contaminated)
G Caliper/disc misaligned
G Caliper dirty or damaged
G Brake line damaged or lining ruptured
G Worn disc and/or friction pads
G Incorrectly adjusted lever
G Incorrectly adjusted stationary pad
G Worn or damaged master cylinder or components
G Improper clearance between lever and switch
Lever Vibration
G Disc damaged
G Disc worn (runout or thickness variance exceeds
service limit)
Caliper Overheats (Brakes Drag)
G Compensating port plugged
G Pad clearance set incorrectly
G Auxiliary brake pedal incorrectly adjusted
G Brake lever or pedal binding or unable to return
fully
G Parking brake left on
G Residue build up under caliper seals
G Operator riding brakes
Brakes Lock
G Alignment of caliper to disc.
9.19