Seeing my dealer has no service manual for my 99 Explorer I am asking someone who can tell me the procedure for installing new brake pads on the front of my machine. Someone told me thats its a tricky job-something about the allenhead bolt adjustment???? Would appreciate some feedback as really don!t want to go to the dealer for this. Thanks in advance. Pete/NY

 

The procedure is not tricky at all.

Call the dealership to find out if they have the heavy duty brake pads in stock. Do not opt for the standard ones.

Mosey on down to your local Polaris dealer and purchase the set of the Heavy Duty pads.

Do not grimace after you hear the price while reaching for your wallet. Keep a straight face and act like you have done this before.

1. Jack up ATV and remove front wheels
2. Do not loosen the allen screw on the front caliper yet.
3. Examine the mounting of brake caliper, what you are looking for are two bolts that hold the caliper to the axle.
4. Remove two bolts with 9/16 heads holding the caliper to the front axle
5. Compress brake piston back into caliper (make sure parking brake is off before attempting this.
6. Depress the end of the bolt opposite the bolt with the allen screw
7. Position pads so that they lift off of this bolt first
8. Remove pads
9. Examine pads for even wear across the surface of the pad. A well adjusted pad will have even wear on both ends. This is what the allen screw adjustment is for. If the wear is straight leave the allen screw alone. If it is worn more on one side of the pad than the other make the appropriate adjustment.
10. Install pads in reverse order.
11. Remount calipers and wheels.
12. Lean back and open an adult beverage relishing the fact that you did it yourself and avoided the usual $60 per hour shop fee.


You will find that the inside pad is worn more than the outside ones. Throw the inside ones away save the outers. They will come in handy if you want to sell the machine and don't want to invest in a new set of shoes before you sell it. Or... you need to get in a ride before pay day sometime in the future.

 

Thor- thanks for your reply. You must be the ONLY guy on this board that has changed their own brake pads! I bought the HD ones and changed them. After I did it I opened the beer! By the way, the pads that I took off were only a hair thinner than the new ones. Thanks again.

 

Pete/ny,I dont understand why you installed new pads if the old ones were allmost as thick as the new ones?

I'd like to add one thing to Thor's proceedure.Next time,be sure to clean and lube the arm that ride/slide inside the caliper.Not doing this will also cause uneven brake pad wear.You will see 2 tiny rubber boots that cover this slide.Completely pull this brake slide out of there.Take the brake slide you just removed and clean it very well.Re-lube everything with a small amount of waterproof grease.If this was done sucessfully,you will be able to slide the brake slide in and out of the caliper with EASE.
Bill

 

MUDDY4LIFE- Thanks also. I had already gotten the pads before I looked at the old ones. I have 2 seasons on the originals and from all I have been told, these pads wear out within a very short time. I didnt want to get them apart and then have to wait for new ones as our dealer around here usually stocks 1 of everything and when thats gone, he will order another-sometimes a week or so later. I dont want to have to order and wait.

 

pete/ny,
if you do not mud very much,the stock pads will last awhile,however,put the Xplorer in alot of mud like me,and you will have allready replaced brakes front/rear 5 times in 1300 miles.Did you do what Thor said and buy the severe duty pads?Hope so,they last alot longer than stock.

I have also installed a set of 100% brass brake pads because I mud to much and am sick and tired of replacing pads.These will out last ANY pad on todays market by at least 2-1,probably more.
Bill



Dynoport pipe/silencer
Delta V-Force reeds/spacer
KN filter
26 inch Mudrunners

 

Pete/ny - I'm in the same shoes you are in. My problem is I can't get the new pads to go on. Should the new ones go on with ease or are they a little tricky?

 

polarisz71,
first,make sure tht the caliper piston is squeezed back into the caliper completely.With your pads removed,take a pair of channel locks and squeeze the piston back in completely.Make sure you loosen the master cyclinder cap slightly before doing this.Dont forget to re-tighten it either.

Second,
the arm that holds your pads on?Make sure that this arm is COMPLETELY squeezed all the way inside the caliper housing.This is what usually causes problems re-installing pads.The pads will go on to one of the arms that secure the pads,but it wont slide over the other arm.Squeeze this arm in tightly,and it will make installation a breeze.This entire arm should slide in and out of the caliper housing with ease,if not,take it completely out and clean it up and use water proof grease when re-installing it into the caliper housing,good luck,
Bill Ciliberti

00 Xplorer 400cc
Dynoport pipe/silencer
RcR airbox mod
Delta V-Force reeds/spacer
26 inch Mudrunners
KN filter

 

pete

Since you are already done, this is just fyi. I take a can of brake cleaner and spray the entire caliber down and clean all of the mud and grease off the caliber. I then take real fine sandpaper and clean up any debris that I can't get off with a rag. I also lightly sand the slide arm wear the pads slide to ensure that the pads will not get bound up. Also, clean the rotor real good with brake cleaner to ensure that their is no grease or mud on them.