Front Caliper Inspection; Front Caliper Assembly - Polaris RZR 900 2015 Service Manual

BRAKE SYSTEM

FRONT CALIPER INSPECTION

1. Inspect caliper body for nicks, scratches, pitting or
wear. Measure bore
specifications. Replace if damaged or worn beyond
service limit.
MEASUREMENT
Front Caliper Piston Bore I.D.:
Std: 1.373" (34.87 mm)
Service Limit: 1.375" (34.93 mm)
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Std: 1.370" (34.80 mm)
Service Limit: 1.368" (34.75 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
9926814 R08 -
9.20
size and compare to
2015-2016 RZR 900

FRONT CALIPER ASSEMBLY

w
1. Install new O-rings
q
grooves are clean and free of residue or brakes
may drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.
3. Lubricate the mounting bracket pins
grease and install the rubber dust seal boots.
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.
in the caliper body. Be sure the
e
with silicone
2016 RZR S 1000 Service
Manual
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