Front Brake Disc; Disc Inspection / Removal / Replacement; Rear Brake Pad; Pad Removal - Polaris Ranger 500 2x4 2007 Service Manual

BRAKES

FRONT BRAKE DISC

Disc Inspection
1. Visually inspect the brake disc for nicks, scratches, or
damage.
2. Measure the disc thickness at 8 different points around the
pad contact surface using a 0-1"micrometer. Replace disc
if worn beyond service limit.
Brake Disc Thickness
New .150-.165" (3.81 - 4.19 mm)
Service Limit .140"/3.56 mm
Brake Disc Thickness Variance
Service Limit .002" (.051 mm)
difference between measurements
3. Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specifications.
Brake Disc Runout
Service Limit .010" (.254 mm)
9.18
Disc Removal / Replacement
1. Remove bolts and disc.
Disc
Hub
2. Clean mating surface of disc and hub.
3. Install disc on hub.
4. Install new bolts and tighten to 18 ft.lbs. (24 Nm).
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.

REAR BRAKE PAD

Pad Removal

1. Elevate and support rear of machine.
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur
if machine tips or falls.
2. Remove the rear wheel. Loosen pad adjuster screw 2-3
turns.
Bolts
18 ft. lbs.
(24 Nm)
CAUTION
CAUTION