Rear Brake Disc - Polaris MS4000 Service And Owner's Manual

BRAKES

REAR BRAKE DISC

Disc Inspection
1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2. Use a 0-1"micrometer and measure disc thickness at 8
different points around perimeter of disc. Replace disc if
worn beyond service limit.
Rear
Disc
Brake Disc Thickness
New .188" (4.78 mm)
Service Limit .170" (4.32 mm)
Brake Disc Thickness Variance
Service Limit .002" (.051 mm)
difference between measurements
3. Mount a dial indicator and measure disc runout. Slowly
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds specification.
Brake Disc Runout
Service Limit .010" (.254 mm)
Disc Replacement
1. Remove rear brake caliper (see "REAR CALIPER
SERVICE").
2. Remove dust cap, cotter pin, castle nut and washers.
9.32
Measure
Thickness
3. Remove the wheel hub assembly from the vehicle and
remove the (4) bolts retaining the disc to the hub.
(4) Bolts
Washers
Nut
4. Clean the wheel hub mating surface and install new disc on
wheel hub.
5. Install new bolts and torque to 28 ft. lbs. (38 Nm).
28 ft. lbs.
(38 Nm)
110 ft. lbs.
(150 Nm)
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
6. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 110 ft. lbs. (150 Nm) and install a new
cotter pin before installing the dust cap.
7. Install rear brake caliper (see "REAR CALIPER
SERVICE"). Follow the bleeding procedure outlined
earlier in this chapter.
8. 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 pedal is released. If the brake
drags, re-check assembly and installation.
Dust
Cap
Cotter
Pin
CAUTION