Brake Pad Inspection; Auxiliary Brake Testing - Polaris SPORTSMAN 600 2003 Service Manual

MAINTENANCE MAINTENANCE

BRAKE PAD INSPECTION

Pads should be changed when the friction material is
worn to 3/64² (.1 cm), or about the thickness of a dime.
HOSE/FITTING INSPECTION
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.

AUXILIARY BRAKE TESTING

The auxiliary brake should be checked for proper
function.
Auxiliary Brake
Support the rear wheels off the ground.
While turning the rear wheels by hand, apply the
auxiliary foot brake. This brake should not stop the
wheels from turning until the lever is half way between
its rest position and bottoming on the footrest.
3/64²
(.1cm)
Minimum
Thickness
Auxiliary Foot Brake
Pedal
Full Height
Floor
Board Surface
AUXILIARY BRAKE
ADJUSTMENT (HYDRAULIC)
Use the following procedure to inspect the hydraulic
auxiliary (foot) brake system and adjust or bleed if
necessary:
First, check foot brake effectiveness by applying 50 lb.
(approx.) downward force on the pedal. The top of the
pedal should be at least 1 inch, (25.4mm) above the
surface of the footrest.
1/8, to 1/4,
Free Play
50 lbs
If less than one inch, two things must be examined:
Free Play:
Free play of the brake pedal should be 1/8 - 1/4
inch (3.2 - 6.35 mm).
If free play is excessive, inspect pedal, linkage, and
master cylinder for wear or damage and replace any
parts as needed.
Bleeding:
If free play is correct and brake pedal travel is still
excessive, air may be trapped somewhere in the
system. Bleed the hydraulic auxiliary brake system in
Full
Engagement
1² or greater
Floorboard
2.27