Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 228 / 289

GENERAL INFORMATION
9.20
REAR BRAKE DISC
INSPECTION
1. Visually inspect disc for scoring, scratches, or
gouges. Replace the disc if any deep scratches
are evident.
Measure
Thickness
Rear Brake
Disc
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.
Brake Disc Thickness
Service Limit .168
″
(4.27 mm)
New .178-.198
″
(4.52-5.03 mm)
Brake Disc Thickness Variance
Service Limit .002
″
(.051 mm)
difference between measurements
3. Mount dial indicator and measure disc runout.
Replace the disc if runout exceeds specifications.
Brake Disc Runout
Service Limit .010
″
(.254 mm)
TROUBLESHOOTING
Brakes Squeal
S
Dirty/contaminated friction pads
S
Improper alignment
S
Worn disc
S
Worn disc splines
S
Poor Brake Performance
S
Air in system
S
Water in system (brake fluid
contaminated)
S
Caliper/disc misaligned
S
Caliper dirty or damaged
S
Brake line damaged or lining
ruptured
S
Worn disc and/or friction pads
S
Incorrectly adjusted lever
S
Incorrectly adjusted stationary pad
S
Worn or damaged master cylinder or
components
S
Improper clearance between lever
and switch
Lever Vibration
S
Disc damaged
S
Disc worn (runout or thickness
variance exceeds service limit)
S
Caliper Overheats (Brakes Drag)
S
Compensating port plugged
S
Pad clearance set incorrectly
S
Auxiliary brake pedal incorrectly
adjusted
S
Brake lever or pedal binding or
unable to return fully
S
Parking brake left on
S
Residue build up under caliper seals
S
Operator riding brakes
Brakes Lock
S
Alignment of caliper to disc.