Service Manual

11.14
BRAKES
BRAKE DISC SERVICE
Disc Inspection
1. Visually inspect the brake disc for scoring, scratches, or
gouges. Replace the disc if any deep gouges are evident.
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.
2. Mount a dial indicator as shown and measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds specification.
Disc Removal / Replacement
1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the brake
disc is being serviced.
3. Remove the wheel nuts and wheel.
4. Remove the cotter pin, castle nut and cone washers.
= In. / mm.
Brake Disc Thickness
New: .187” (4.75 mm)
Service Limit: .167” (4.24 mm)
= In. / mm.
Brake Disc Thickness Variance
Service Limit: .002” (.051 mm)
(difference between measurements)
= In. / mm.
Brake Disc Runout
Service Limit: 010” (.254 mm)
CAUTION
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if
machine tips or falls.
Image shown is
for reference only.
Castle Nut
Cotter Pin
Cone
Washers