Polaris Outlaw 500, Service Manual

Page: 164 / 202

6.15
BRAKES
6
FRONT BRAKE PADS
Pad Removal
1. Elevate and support front of ATV.
2. Remove the front wheel. Loosen pad adjuster screw 2-3
turns.
3. Remove caliper from mounting bracket.
NOTE: When removing caliper, use care not to
damage brake line. Support caliper so to avoid
kinking or bending brake line.
4. Push caliper piston into caliper bore slowly using a
C-clamp or locking pliers with pads installed.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
5. Push mounting bracket inward and slip outer brake pad
past edge. Remove inner pad.
6. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
CAUTION
Use care when supporting vehicle so that it
does not tip or fall.
Severe injury may occur if machine tips or falls.
Front Brake Pad Thickness
New : .298”/ 7.6 mm
Service Limit: .180” / 4.6 mm
Measure Pad