While doing my spring maintenance on my ’11 800 Trail last week, I measured my factory brake pad thickness with calipers and came up with an average of 0.125". Looking in my manual and on-line, I was not able to determine what the service limit was, so I went to the local Polaris dealer to ask. The service manager had no idea. The lead mechanic in the shop had no idea. Finally the SM found a service bulletin that said factory organics new is 0.30" and the service limit is 0.18". That told me I was overdue for new pads but as the dealer wanted $139, I thought I would do a little research.

Interested in sintered, I browsed the internet and this Forum and came to the conclusion the severe duty sintered offered by Race Driven would fit my needs. I ordered a set and received them Monday. However, they looked not much thicker than the ones I am about to replace. Measured the new at 0.14.

Called Race Driven on Tuesday to ask why their sintered pads were so thin and received an answer that because of the sintering the thickness does not need to be as thick as organics, though will outlast organics by a factor of five depending upon use. Made sense until I asked the next question –

What is the service limit on the sintered? Or rather, at what thickness should I consider replacement pads?

Their answer was "Nobody has ever asked that question." Really????? I posed it again that as a preventive maintenance item, I need to know. She put me on hold, then came back stating nobody knew, but most folks order rotors at the same time as pads. Really?????? She then stated she would ask the owner and get back to me.

Today, I called again and lucked out (??) by getting the same lady as the day before. She said the owner said "they don’t have a clue and most people replace pads when they are worn out." Really??????????

So to make a long story short, does anyone know what the service limit is on sintered pads? Why destroy rotors when it is totally unnecessary.