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changing brake pads on xc 700
started by xc700
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August 1st 2004 at 11:09 AM
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xc700
Disturbed
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9 Posts
Group: Members
Member Since: May 17th 2004
Location: dunkirk, ny, USA
Current Sled: 98 xc 700,01xc700,02xc500
2008-2009 Miles: 385
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I need to change the brake pads on my 1998 xc 700 and need to know how to do it with out getting antifreeze all over everything.I don't have a repair manual to use. any help would be appreciated.
thanks
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Site Supporter
Group: Site Supporters
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August 1st 2004 at 3:01 PM
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TriumphoverU
The Sled Guru - Moderator
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2192 Posts 
Group: Moderators
Member Since: June 19th 2001
Location: Saint Johns, MI, USA
Current Sled: 2006 Polaris Fusion 700
2008-2009 Miles: 600
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Here is the sequence direct from the shop manual. But it looks like you will end up getting antifreeze all over everything according to their directions.
1. Clean any dirt from mount bracket and bolts.
2. With a 9/16" socket, remove two 3/8' hex bolts and washer from bracket. Remove rope guide. NOTE: Do not disconnect brake line
3. Remove hose clamp from ENGINE side of cooler. Twist and remove hose from cooler, catching and disposing of antifreeze properly.
4. Use a drop cloth to protect surfaces from brake fluid spillage. Remove reservoir cover. Using a large hardwood dowel, or a C-clamp vise grip on the center of the old pads, apply pressure toward the caliper piston. Compress piston back into caliper assembly. Apply pressure slowly to prevent excessive spillage from master cylinder assembly.
NOTE: Pusing the piston back into the bore will cause the fluid level to rise in the reservoir and possibly overflow.
5. Lift bracket and brake assembly off vehicle. Raise open end of cooler and pad assembly to trap antifreeze in cooler and plug the opening of both the cooler and engine hose open end.
6. Place new pads with friction material facing each other into housing. Hold in place using spring clips.
7. Slide brake assembly into bracket until both clips snap into grooves in bracket.
8. Clean top of chaincase where brake mounts.
9. Seperate pads for installation over disc. If brake assembly does not slide easily over the disc with loose pads the piston is not compressed far enough into the caliper. The caliper assembly must fit freely onto the disc and chaincase.
10. Remove Plugs. Install coolant hose and clamp on cooler assembly.
11. Replace 3/8" bolts, washers, and rope guide. Torque to 25-30 ft. lbs.
12. Actuate brake several times to set brake pads to proper operating position.
13. Check for proper fluid level in master cylinder and replace cover.
14. Be sure to bleed coolant system
15. Bleed brake system
16. Field test at low speeds before putting into regular service.
Polaris is my way out - Other people just use a door.
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August 1st 2004 at 7:00 PM
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xc700
Disturbed
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9 Posts
Group: Members
Member Since: May 17th 2004
Location: dunkirk, ny, USA
Current Sled: 98 xc 700,01xc700,02xc500
2008-2009 Miles: 385
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Thanks for the information, I kind of thought I would get antifreeze all over everything.
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August 1st 2004 at 7:08 PM
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ripperd
kick@$$
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7425 Posts 
Group: Members
Member Since: November 7th 2001
Location: Brooklyn Center, MN, USA
Current Sled: 07 Rev 600 mod
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That is really crappy! Neither my 02 or 92 require removal of any parts besides clips to replace brake pads! Although the 92 ones are a PITA, they still are just two pins and two clips to hold them in. the 02 is just one straight pin, pull the pin, pull the pads up, put new pads down, replace pin, that easy.
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August 2nd 2004 at 4:02 PM
[ Modified August 3rd 2004 at 6:08 PM
]
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xcr440
Sundowners Trail Coordinator
xcr440 icefish's because having feeling in your fingertips is overrated.
Updated Yesterday at 10:49 PM
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12582 Posts
Group: Members
Member Since: February 1st 2003
Location: St.Germain/Edgerton, Wisconsin, USA
Current Sled: 03prox700/97xcr440
2008-2009 Miles: 610
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don't have to remove hose. Just finished changing mine. Takes alittle patience and some wiggling. can be done without removing the hose.
a good beer drinker isnt a picky beer drinker
Loggers.... Working their ass off so you can wipe yours!
"Steep ground is when your cutting a notch and notice a mountain goat looking at you like you are crazy." - Hexan
woodbooga: (WOOD-boog-ah), n. regional dialect, common to areas of New Hampshire and Maine including the towns of Ossipee, Alton, Farmington, Acton, and Lebanon; one who attempts to obtain free firewood to fuel woodburning appliances in an effort to mitigate expenses related to home heating with fossil fuels. Frequently used as a term of derision by non-woodburners who mock the presence of loose bark and other wood waste in the beds of their pickup trucks.
2003 Pro x 700 almond/blue,10-66 black/red team 719 T-flow, 440 mains
1997 xcr440 my clutch kit, 380 mains,T-flow
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August 3rd 2004 at 9:09 AM
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Quote Originally posted by ripperd2
That is really crappy! Neither my 02 or 92 require removal of any parts besides clips to replace brake pads! Although the 92 ones are a PITA, they still are just two pins and two clips to hold them in. the 02 is just one straight pin, pull the pin, pull the pads up, put new pads down, replace pin, that easy.
Hey, Ripperd, is my '02 600 XC the same "drop-in" setup as yours?
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August 4th 2004 at 6:43 AM
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ripperd
kick@$$
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7425 Posts
Group: Members
Member Since: November 7th 2001
Location: Brooklyn Center, MN, USA
Current Sled: 07 Rev 600 mod
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Hmm, maybe, but probably not. The 02 race sleds usually have the same stuff as the 03 consumer sleds. Heres a pic if you want to look closer and see if it looks like yours:
http://www.ripperd.com/cgi-bin/gallery/i...Width=9999
(beware, huge pic)
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August 4th 2004 at 8:28 AM
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torkerob
Advanced Member
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1621 Posts 
Group: Members
Member Since: January 31st 2004
Location: Tillsonburg, ON, Canada
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I have a 98 600xc and it is a pain to change the pads. I have not had to change them yet but have looked over the job and that style of liquid cooled calipers are alot more work to change then older or newer machines.
98 600XC
00 VS1400
Tillsonburg, Ontario
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August 4th 2004 at 8:08 PM
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