Service Manual

11.16
BRAKES
12. Torque wheel hub nut to specification and install a new
cotter pin. Tighten nut slightly if necessary to align cotter
pin holes.
13. Install the wheel and (4) wheel nuts. Torque wheel nuts to
specification.
14. Field test the ATV for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes. Make
sure the brake is not dragging when lever is released. If the
brake drags, re-check assembly and installation.
TROUBLESHOOTING
Brake Squeal
• Dirty/contaminated friction pads
• Improper alignment
• Worn disc
• Worn caliper
• Glazed brake pads
Poor Brake Performance
• Air in system
• Water in system (brake fluid contaminated)
• Caliper/disc misaligned
• Caliper dirty or damaged
• Brake line damaged or lining ruptured
• Worn disc and/or friction pads
• Incorrectly adjusted stationary pad
• Worn or damaged master cylinder or components
Lever / Pedal Vibration
• Disc damaged
• Disc worn / warped (runout or thickness variance
exceeds service limit)
Caliper Overheats (Brakes Drag)
• Compensating port plugged
• Brake lever or pedal binding or unable to return fully
• Parking brake left on
• Residue build up under caliper seals
• Operator riding brakes
Brakes Lock
• Alignment of caliper to disc
• Reservoir is overfilled with fluid
• Master cylinder compensating port plugged
• Caliper piston is stuck
• Parking brake left on
= T
Wheel Hub Castle Nut:
80 ft. lbs. (108 Nm)
= T
Wheel Nuts:
Steel Wheels: 45 ft. lbs. (61 Nm)
Aluminum Wheels: 75 ft. lbs. (102 Nm)
NEW
80 ft. lbs.
(108 Nm)
Cotter Pin