Service manual

BRAKES
BRAKE SYSTEM SERVICE NOTES
Disc brake systems are light weight, low maintenance,
and perform well in the conditions ATVs routinely
encounter. There are a few things to remember when
replacing disc brake pads or performing brake system
service to ensure proper system function and maximum
pad service life.
◎ Optional pads are available to suit conditions in your
area. Select a pad to fit riding style and environment.
◎ Do not over-fill the master cylinder fluid reservoirs.
◎ Make sure the brake levers return freely and
completely.
◎ Check and adjust master cylinder reservoir fluid levels
after pad service.
◎ Make sure atmospheric vent on reservoirs are
unobstructed.
◎ Test for brake drag after any brake system service
and investigate cause if brake drag is evident.
◎ Make sure caliper moves freely on guide pins.
◎ Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
◎ Perform a brake burnishing procedure after installing
new pads to maximize service life.
Use only DOT 4 brake fluid as an assembly aid for all
procedures described in this chapter to prevent
brake system contamination.
DO NOT USE LUBRICANTS OF ANY KIND FOR
ASSEMBLY.
DISC BRAKE NOISE TROUBLESHOOTING
Dirt or dust buildup on the brake pads and disc is the
most common cause of brake noise (squeal caused by
vibration). If cleaning does not reduce the occurrence of
brake noise, check the backing of each pad for worn
spots allowing metal to metal contact. See table below.
Brake Noise Troubleshooting
Possible Cause Remedy
Dirt, dust, or imbedded material on pads or disc Spray disc and pads with a non-flammable aerosol brake
cleaner only! Remove pads and/or disc hub to clean
imbedded material from disc or pads.
Pad(s) dragging on disc (noise or premature pad wear)
Improper adjustment
Insufficient lever or pedal clearance
Master cylinder reservoir overfilled
Master cylinder compensating port restricted
Master cylinder piston not returning completely
Caliper piston(s) not returning
Operator error (riding the brake / park brake applied)
Adjust pad stop.
Check position of controls & switches.
Set to proper level
Clean compensating port
Inspect. Repair as necessary
Clean piston(s) seal
Educate operator
Loose wheel hub or bearings Check wheel and hub for abnormal movement.
Brake disc warped or excessively worn Replace disc
Brake disc misaligned or loose Inspect and repair as necessary
Noise is from other source (chain, axle, hub, disc or
wheel)
If noise does not change when brake is applied check
other sources. Inspect and repair as necessary
Wrong pad for conditions Change to a softer or harder pad
8.3