Can-Am Maverick X3 Wilwood Front Brake Kit

Torque Specifications

1. Step 1

   Disassemble the original equipment front brakes. Raise the front wheels off the ground and support the front suspension according to the vehicle manufacturer's instructions. Remove the front wheels, calipers, wheel hubs, and rotors. Remove any nicks or burrs on the wheel hub and upright that may interfere with the installation of the new brake components. Clean and de-grease the wheel hub, and upright.

1. Step 2

   NOTE: Some grinding of the casting line on the outer edge of lower caliper mounting tab of upright may be required for proper fitment of new caliper. If necessary, only grind off enough material to provide adequate clearance so that the Wilwood caliper does not touch the mounting tab and properly attaches to caliper mounting bracket without any binding, see Photos A and B at right.

   

   

1. Step 3

   Place the existing OEM wheel hub face down and position the rotor adapter (1) onto the wheel hub as shown in Figure 1 and Photo 1.

   

   Note

   The existing wheel hub must be free of dirt and debris or excessive rotor run out may result.

2. Step 4

   Position the rotor (2) onto the rotor adapter (1), making sure the rotor lugs fit into the recesses of the rotor adapter, as shown in Photo 2. Place the adapter ring (3) onto the assembly and attach using bolts (4), Photos 3 and 4. Using an alternating sequence, apply red Loctite 271 to the threads of the bolts (4) and torque to value shown in Figure 1.

   • Torque240 in-lbsBolts (4) M8 rotor adapter bolts
3. Step 5

   Grease the splines and outer snout of the existing wheel hub and slide the wheel hub/rotor assembly onto the axle and attach using the existing OEM washer and castle nut. Tighten to OEM specifications and secure using cotter pin (5), Photo 5. Reinstall the existing dust cap, Photo 6.

4. Step 6

   Orient the caliper mounting bracket (6), as shown in Figure 1 and Photo 7. Install using bolts (7) and washers (8). Apply red Loctite 271 to the bolt threads and torque to value shown in Figure 1.

   • Torque35 ft-lbsBolts (7) M10 caliper mounting bracket bolts
5. Step 7

   Secure the caliper (9) to the mounting bracket (6) using bolts (10) and washers (11), as shown in Figure 1 and Photo 8. Apply red Loctite 271 to the threads and torque to value shown in Figure 1.

   

   • Torque35 ft-lbsBolts (10) M10 caliper-to-bracket bolts
6. Step 8

   Remove the pad retainer clip from the caliper (9). Insert the brake pads into the caliper with the friction material facing the rotor, as shown in Photo 9. Reinstall the pad retainer clip, Photo 10.

   

7. Step 9

   Temporarily install the wheel and torque the lug nuts to the manufacturer's specification. Ensure that the wheel rotates freely without any interference. Remove wheel for next step.

   

   Note

   A MINIMUM OF .090" CLEARANCE MUST BE MAINTAINED BETWEEN THE WHEEL AND CALIPER IN ALL AREAS.

1. Step 10

   Attach brake line to caliper. Orient OEM brake line as shown in Photo 11 and connect to caliper using banjo bolt (13) and crush washers (14). Do not use lubricant or thread sealant on banjo bolt (13). Torque to minimum value shown in Figure 1. Check for leakage, increasing torque only to stop leakage without exceeding maximum specification. Replace crush washers and banjo bolt whenever reassembly is required. Ensure hoses are routed to prevent contact with moving suspension, brake or wheel components.

   Warning

   In absence of specific instructions for brake line routing, the installer must use best professional judgment on correct routing and retention of lines to ensure safe operation. It is the installer's responsibility to properly route and provide adequate clearance and retention for brake hose components. It is also the installer's responsibility to ensure that all fittings and hoses are the correct size and length, properly seat, and that they will not be subject to crimping, strain and abrasion from vibration or interference with suspension components, brake rotor or wheel.

   Note

   The caliper in this brake kit utilizes a 10mm x 1.25 thread inlet, the same as the Original Equipment Manufacturer (OEM) caliper.

   • Torque96-120 in-lbs, do not exceed 144 in-lbsBanjo bolt (13)
2. Step 11

   Bleed the brake system, referring to the Additional Information and Recommendations for proper bleeding instructions. Check system for leaks after bleeding.

   Caution

   NEVER allow the contact surfaces of the pads or rotors to be contaminated with brake fluid. Always use a catch bottle with a hose to prevent fluid spill during all brake bleeding procedures.

   Warning

   Test vehicle brake system per the Minimum Test Procedure stated within this document before driving. After road testing, inspect for leaks and interference. Initially after install and testing, perform frequent checks of the vehicle brake system and lines before driving, to confirm that there is no undue wear or interference not apparent from the initial test. Afterwards, perform periodic inspections for function, leaks and wear in a interval relative to the usage of vehicle.

3. Step 12

   Install the wheel and torque the lug nuts to manufacturer's specifications.

4. Step 13

   Bed-in the brake pads for the procedure (Pad and Rotor Bedding). Begin with a series of light decelerations to gradually build some heat in the brakes. Use an on-and-off the pedal technique by applying the brakes for 3-5 seconds, and then allow them to fully release for a period roughly twice as long as the deceleration cycle. If you use a 5 count during the deceleration interval, use a 10 count during the release to allow the heat to sink into the pads and rotors. After several cycles of light stops to begin warming the brakes, proceed with a series of medium to firm deceleration stops to continue raising the temperature level in the brakes. Finish the bedding cycle with a series of 8-10 hard decelerations from 55-65 MPH down to 25 MPH while allowing a proportionate release and heat-sinking interval between each stop. The pads should now be providing positive and consistent response. If any amount of brake fade is observed during the bed-in cycle, immediately begin the cool down cycle. Drive at a moderate cruising speed, with the least amount of brake contact possible, until most of the heat has dissipated from the brakes. Avoid sitting stopped with the brake pedal depressed to hold the car in place during this time. Park the vehicle and allow the brakes to cool to ambient air temperature.