How To Replace and Install ATV or UTV Brake Rotors

ventually, you are going to need new brake pads. Pads will fail before the rotor does. When you are replacing brake pads, take the opportunity to inspect the rotor. Run your fingernail across the rotor. If you feel bumps or ridges and valleys it's time to replace the rotor. If the surface looks and feels smooth then eyeball the rotor for warping which is the second most common reason for rotor failure.

Inspecting your pads and rotors is a snap and shouldn't take more than an hour to do all four. Regular inspection will greatly improve the safety of your ride and give you peace of mind knowing that you can make the machine stop before you run into that boulder or tree blocking the trail.

• Replacement rotors
• Jack
• Socket set and ratchet wrench
• Torque wrench
• Flat head screwdriver

While most rotors are non-directional meaning a single rotor can fit either the left or right wheel and there is no "forward" direction like the tread on a tire, not all rotors fit this description. Take time to read the install instructions that come with the rotors and if they are directional make certain you install the correct rotor on the correct wheel.

When you bolt the rotor to the wheel hub you'll want to know what the torque specification is for that operation. If you can't find it in your owner's manual go to the manufacturer's site and see if it is listed there.

1. Loosen the lug nuts on the wheel you are going to install the new rotor.
2. Use the jack to elevate the ATV.
3. Finish loosening the lug nuts and remove the tire.
4. Remove the caliper. Typically it is secured with two bolts. Use a support (like an upside down bucket) to rest the caliper on so it is not dangling by the brake line.
5. Remove the spindle pin in the center of the hub and pull the hub off.
6. On the back of the hub you'll find a series of bolts that are securing the old rotor. Use the socket set to remove these bolts and pull the rotor from the hub.
7. Place the new rotor on the hub and secure it using the bolts you just removed. Check the torque specification in your owner's manual and then torque to spec.
8. Reinstall the hub.
9. Reattach the caliper to using the 2 bolts you removed earlier. If you find that the caliper piston has opened making it difficult to slide the brake pads onto the rotor, use a flat head screw and gently apply pressure to the top of the caliper causing the piston to close. With the piston closed the brake pads will have separated enough to slide the caliper onto the rotor.
10. Mount the wheel on the studs and snug down the lug nuts.
11. Lower the ATV.
12. Finish tightening the lug nuts.

Go easy on the brakes during your first ride after changing rotors. After the ride inspect the rotors to ensure the bolts securing the rotor to the hub are tight and that the rotor has not moved out of position. It sounds like extra work but it's well worth the time to ensure you have full braking power.

- End of Procedure -

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