2-9
2
2. Loosen both jam nuts on the right-hand (front)
brake lever. Turn both cable adjusters counter-
clockwise until both front wheels do not spin
freely.
KM024B
3. Turn both cable adjusters in 1/4 turn increments
(clockwise) until the wheels spin with a very slight
amount of drag.
4. Lower ATV; then push it forward and compress
the brake lever.
5. If the front wheels lock evenly, adjustment is cor-
rect.
6. If the front wheels do not lock evenly, additional
adjustment is necessary.
7. Once proper adjustment is obtained, tighten the
jam nuts.
MEASURING/REPLACING BRAKE
SHOES/PADS
Removing Front Brake Shoes
1. Support the ATV on a support stand.
2. Remove both front wheels and account for the cap
screws.
3. Remove the cotter pins, castle nuts, and washers;
then remove the brake drums/wheel hubs.
4. Loosen the brake shoe return spring; then remove
the brake shoes.
MD2042
Removing Rear Brake Pads
1. Remove the two cap screws securing the brake
caliper to the axle housing; then lift the caliper off
the disc.
KM234A
2. Depress the holder pins and disengage and remove
the outer pad; then remove the inner pad. Account
for the spring clip.
KM221A
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 any brake pad is less than 1.0
mm (0.039 in.), the brake pads 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.
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