Pedal Removal And Installation; Troubleshooting; Brakes Squeal; Poor Brake Performance - Polaris 2007 Sportsman 500 EF Service Manual

Pedal Removal and Installation

X2 Shown
1. Remove the RH footwell to gain access to the rear master
cylinder.
2. Remove the cotter key.
3. Remove the washers, bushings, and tension spring.
4. Reverse the steps for installation, use a new cotter key
during installation.

TROUBLESHOOTING

Brakes Squeal

• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn disc splines

Poor Brake Performance

• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted lever
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
• Improper clearance between lever and switch

Lever Vibration

• Disc damaged
• Disc worn (runout or thickness variance exceeds
service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged
• Pad clearance set incorrectly
• Auxiliary brake pedal incorrectly adjusted
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes

Brakes Lock

• Alignment of caliper to disc
BRAKES
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