Caliper Inspection; Caliper Assembly - Polaris 2012 RANGER RZR 570 INTL Service Manual

BRAKES

Caliper Inspection

1. Inspect ca liper b ody for n icks, scratches, pitting or
wear. Measure bor e size and
specifications. Re place if da maged or wo rn b eyond
service limit.
Front Caliper Piston Bore I.D.:
Std: 1.004" (25.5 mm)
Service Limit: 1.006" (25.55 mm)
2. Inspect pist on fo r nic ks, scratches, pitting or wear .
Measure piston diameter and replace if damaged or
worn beyond service limit.
Front Caliper Piston O.D.:
Std: 1.002" (25.45 mm)
Service Limit: 1.000" (25.4 mm)
3. Inspect the br ake disc and pa ds as o utlined in th is
chapter.
9.18
compare to
= In. / mm.
= In. / mm.
9923523 - 2012 RANGER RZR 570 Service Manual
© Copyright 2011 Polaris Sales Inc.

Caliper Assembly

1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing
inward. Pisto n sh ould slide in
smoothly, with light resistance.
3. Lubricate the mounting
grease and install the rubber dust seal boots.
Apply Grease to Each
Bracket Pin
4. Compress the mounting bracket and make sure the
dust seal boots are fully seated. Install the brake pads.
Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.
Seal
Grooves
and ou t of b ore
bracket pins w ith silicone