14
MD2042
Removing Rear Brake Pads
1. Remove the two brake pad alignment pins (A); then
remove the mounting cap screws (B).
KM273A
2. Remove the caliper from the disc; then compress the
caliper holder and remove the brake pads.
KM267
Inspecting and Measuring
1. Inspect the pads for gouges, chips, or wear.
2. Inspect the disc for gouges, grooves, cracks, and
warpage.
3. Using a calipers, measure the thickness of each brake
pad.
4. If the thickness of either brake pad is less than 1.0
mm (0.039 in.), the brake pad must be replaced.
NOTE: The brake pads should be replaced as a set.
Installing Front Brake Shoes
1. Place the brake shoes onto the backing plate over the
stationary pivot pin and rotating cam.
2. Install the brake return spring.
MD2044
3. Install the wheel hub, washer, and castle nut. Tighten
the castle nut to 50 ft-lb; then install a new cotter pin.
4. Install the wheel. Tighten to 32 ft-lb.
5. Repeat this procedure for the other side; then adjust
the brake.
6. Remove the ATV from the support stand.
Installing Rear Brake Pads
1. Install new brake pads; then install the two brake pad
alignment pins.
2. Spread the brake pads and place the brake caliper
over the disc; then secure with the mounting cap
screws (B). Tighten the cap screws to 24 ft-lb; then
tighten the alignment pins (A) to 13 ft-lb.
KM273A
NOTE: Whenever installing new pads, the new pads
must be burnished.
BLEEDING
1. Remove the brake fluid reservoir cover and fill the
reservoir with DOT 4 Brake Fluid.
2. Install and secure the cover.
3. Remove the protective cap from the bleed screw and
connect one end of a clear hose to the bleed screw
and direct the other end into a suitable container.
