Polaris Ranger 500 2x4 2007, Service Manual

Page: 59 / 345

2.38
MAINTENANCE
BRAKE SYSTEM
Brake System Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the master cylinder reservoir to the
indicated level inside reservoir.
• Use Polaris DOT 3 or DOT 4 Brake Fluid.
• Check brake system for fluid leaks.
• Check brake for excessive travel or spongy feel.
• Check friction pads for wear, damage or looseness.
• Check surface condition of the disc.
Brake Pad Inspection
Pads should be changed when the friction material is worn to
.180" (4.6 mm). When the pad are new the thickness is .298 ±
.007" (7.56 ± .178 mm).
Parking Brake Pad Inspection
Measure the thickness of the rear caliper parking brake pads.
Replace assembly as needed. See illustration below for proper
readings.
Brake Hose and Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks. Tighten any loose fittings and replace any
worn or damaged parts.
Brake Pad
Service Limit - .180" (4.6 mm)
Measure
Thickness
Inboard
Pad
Outboard
Pad
Inboard Pad Thickness
New .304” (7.72 mm)
Limit: 0.24” (6.1 mm)
Outboard Pad Thickness
New 0.360” (9.14 mm)
Limit: 0.31” (7.87 mm)
Installed Disc to Park Brake
0.375” (0.953 cm)
New Rotor Disc Thickness
0.150” - 0.164”
(3.81 - 4.16 mm)