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BRAKES
6.3
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.
G Optional pads are available to suit
conditions in your area. Select a pad to fit
riding style and environment.
G Do not over-fill the master cylinder fluid
reservoirs.
G Make sure the brake levers return freely
and completely.
G Check and adjust master cylinder
reservoir fluid levels after pad service.
G Make sure atmospheric vent on reservoirs
are unobstructed.
G Test for brake drag after any brake system
service and investigate cause if brake
drag is evident.
G Make sure caliper moves freely on guide
pins.
G Inspect caliper piston seals for foreign
material that could prevent caliper pistons
from returning freely.
G Perform a brake burnishing procedure
after installing new pads to maximize
service life.
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. 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 (front calipers)
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
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