Pad Assembly / Installation / Adjustment - Polaris Ranger 500 2x4 2007 Service Manual

BRAKES
Front Brake Pad Thickness:
New: 298" (7.56 mm) + .007" (.178 mm)
Service Limit: .180"/4.6 mm
Pad Assembly / Installation
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease, and install rubber
dust boots.
Polaris Premium All Season Grease
(PN 2871423)
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other. Be sure pads and disc are free of dirt or grease.
3. Install caliper on hub strut, and torque mounting bolts.
Front Caliper Mounting Bolts
Torque 18 ft. lbs. (24 Nm)
9.14
4.
Pad Adjustment
1.
2.
3.
4.
18 ft. lbs.
(24 Nm)
Slowly pump the brake pedal 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 brake system.
Install the adjuster screw and turn clockwise until
stationary pad contacts disc, then back off 1/2 turn
(counterclockwise).
Be sure fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
Install wheels and torque wheel nuts.
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 procedure 10 times.
Front Wheel Nut Torque:
37 ft. lbs. (50 Nm)
Pad Adjuster Screw