TROUBLESHOOTING
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
4. Push caliper mounting bracket inward and slip outer brake
pad past the edge to remove.
5. Remove the inner brake pad.
PAD INSPECTION
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Rear Brake Pad Thickness
New 10 mm
Service Limit 6.5 mm
PAD ASSEMBLY / INSTALLATION
1. Lubricate mounting bracket pins with a light film of all
season grease, and install rubber dust boots.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
clean pads.
3. Install brake line and tighten securely with a line wrench.
Torque the banjo bolt brake hose to the proper torque
specification.
4. Install caliper and torque mounting bolts to specification.
5. Perform brake-bleeding procedure as outlined earlier in this
chapter.
Front caliper Bolt Torque:
30 Nm (21.7 ft. lbs.)
6. Slowly pump the brake lever until pressure has been built
up. Maintain enough of brake fluid in the reservoir to prevent
air from entering the brake system.
7. Verify fluid level in reservoir is up to the MAX line inside
reservoir and install reservoir cap.
BRAKE BURNISHING PROCEDURE
It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise. Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and disc
to cool sufficiently during the procedure. Do not allow pads or
disc to become hot or warping may result. Repeat this
procedure 10 times.
BRAKE SQUEAL / POOR BRAKE
PERFORMANCE
• Air in system
• Water in system (brake fluid contaminated)
• Caliper or 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
• Damaged break pad noise insulator
• Brake pads dragging
• Brake caliper dragging
PEDAL VIBRATION
• Disc damaged
• Disc worn (run-out or thickness variance exceeds service
limit)
CALIPER OVERHEAT (BRAKES DRAG)
• Compensating port plugged
• Pad clearance set incorrectly
• Brake pedal binding or unable to return fully
• Residue build up under caliper seals
• Operator riding brakes
BRAKE LOCK
• Alignment of caliper to disc
• Caliper pistons sticking
• Improper assembly of brake system components
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