Polaris PREDATOR 2003, Service Manual

Page: 156 / 193

BRAKES
6.11
FRONT 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
s
micrometer. Replace disc if worn beyond service
limit.
Brake Disc Thickness
Service Limit .140
s
/ 3.556 mm
New .150-.164
s
( 3.810-4.166 mm)
Brake Disc Thickness Variance
Service Limit .002
s
(.051 mm)
difference between measurements.
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.
Brake Disc Runout
Service Limit .010
s
(.50 mm)
FRONT BRAKE DISC
REMOVAL / REPLACEMENT
18 ft. lbs. (25 Nm)
Use new bolts with pre-applied
locking agent.
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.
CAUTION: Always use new brake disc mounting
bolts. The bolts have a pre-applied locking agent
which is destroyed upon removal.
5. Install new bolts and tighten to specified torque.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (25 Nm)
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