Front Caliper Inspection - Polaris Sportsman 400 Service Manual

FRONT CALIPER DISASSEMBLY, CONT.
4. Remove piston, dust seal and piston seal.
5. Clean the caliper body, piston, and retaining bracket
with brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper body.

FRONT CALIPER INSPECTION

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.
Front Caliper Piston Bore I.D.
Std. 1.191-1.192" (30.25-30.28 mm)
Service Limit 1.193" (30.30 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
Front Caliper Piston O.D.
Std. 1.186-1.1875" (30.13-30.16 mm)
Service Limit 1.1855" (30.11 mm)
3. Inspect the brake disc and pads as outlined for brake
pad replacement this section. See page 9.16.
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BRAKES
9.19