Brake System Service Notes; Brake Noise Troubleshooting - Polaris RANGER 2x4 Manual

BRAKES
BRAKE SYSTEM SERVICE
NOTES
Disc brake systems are light weight, low maintenance, and perform well in the conditions ATVs routinely
encounter. There are a few things to remember when replacing disc brake pads or performing brake system
service to ensure proper system function and maximum pad service life.
S
Optional pads are available to suit conditions in your area. Select a pad to fit riding style and
environment.
S
Do not over-fill the master cylinder fluid reservoir.
S
Make sure the brake lever and pedal returns freely and completely.
S
Adjust stop pin on front caliper after pad service.
S
Check and adjust master cylinder reservoir fluid level after pad service.
S
Make sure atmospheric vent on reservoir is unobstructed.
S
Test for brake drag after any brake system service and investigate cause if brake drag is evident.
S
Make sure caliper moves freely on guide pins (where applicable).
S
Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning
freely.
S
Perform a brake burnishing procedure after installing new pads to maximize service life.

BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by
vibration). If cleaning does not reduce the occurrence of brake noise, Permatext Disc Brake Quiet (PN
2872113) can be applied to the back of the pads. Follow directions on the package. This will keep pads in
contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.
Possible Cause
Dirt, dust, or imbedded material on pads or disc
Pad(s) dragging on disc (noise or premature pad wear)
Improper adjustment
Insufficient lever or pedal clearance
Master cylinder reservoir overfilled
Master cylinder compensating port restricted
Master cylinder piston not returning completely
Caliper piston(s) not returning
Operator error (riding the brake / park brake
applied)
Loose wheel hub or bearings
Brake disc warped or excessively worn
Brake disc misaligned or loose
Noise is from other source (axle, hub, disc or wheel)
Wrong pad for conditions
Brake Noise Troubleshooting
Spray disc and pads with CRC Brakeleent or an
equivalent non-flammable aerosol brake cleaner. Re-
move pads and/or disc hub to clean imbedded material
from disc or pads.
Adjust pad stop (front calipers)
Check position of controls & switches.
Set to proper level
Clean compensating port
Inspect. Repair as necessary
Clean piston(s) seal
Educate operator
Check wheel and hub for abnormal movement.
Replace disc
Inspect and repair as necessary
If noise does not change when brake is applied check
other sources. Inspect and repair as necessary
Change to a softer or harder pad
Remedy
9.3