Polaris Outlaw 500, Service Manual

Page: 166 / 202

6.17
BRAKES
6
FRONT BRAKE DISC
Disc Inspection
1. Visually inspect the brake disc for nicks, scratches, or
damage.
2. Measure the disc thickness at 8 different points around the
pad contact surface using a 0–1” micrometer. Replace disc
if worn beyond service limit.
3. Mount dial indicator as shown to measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specifications.
Disc Removal / Replacement
1. Apply heat to the hub in the area of the brake disc
mounting bolts to soften the bolt locking agent.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install disc on hub.
5. Install new bolts and tighten to specified torque.
Brake Disc Thickness
New: .158” (4.013 mm)
Service Limit: .140” / 3.556 mm)
Brake Disc Thickness Variance
Service Limit: .002” (.051 mm)
(difference between measurements)
Brake Disc Runout
Service Limit .010” (.254 mm)
CAUTION
Always use new brake disc mounting bolts.
The bolts have a pre–applied locking agent
which is destroyed upon removal.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (24 Nm)
18 ft. lbs.
(24 Nm)