Front Caliper Inspection- Ranger; Front Caliper Assembly - Polaris RANGER 500 2018 Service Manual

FRONT CALIPER INSPECTION- RANGER

1. Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.
MEASUREMENT
Front Caliper Piston Bore I.D.:
Std. 1.5050-1.5040" (32.27-30.202 mm)
Service Limit 1.5060" (38.252 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Std. 1.4985-1.5000" (38.062 - 38.10 mm)
Service Limit 1.4980" (38.049 mm)
3. Inspect the brake disc and pads as outlined for brake
pad replacement in this chapter.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
© Copyright Polaris Industries Inc.

FRONT CALIPER ASSEMBLY

1. Install new square O-rings
sure that the grooves are clean and free of residue or
brakes may drag.
2. Coat the piston with clean Polaris DOT 4 Brake Fluid
(P/N 2872189). Install piston
motion while pushing inward. Piston should slide in
and out of bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with disc brake
caliper lube, and install the rubber dust seal boots.
CAUTION
Do not allow grease to come into contact with the piston
and seals.
Damage may occur to the components.
4. Compress the mounting bracket and make sure the
dust seals 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.
BRAKE SYSTEM
q
in the caliper body. Be
w
with a twisting
9
9.19