Hydraulic Caliper Disassembly - Polaris INDY TRAIL RMK Service Manual

BRAKES / FINAL DRIVE

Hydraulic Caliper Disassembly

1. Carrier Bracket Attaching Bolts
2. Carrier Bracket
3. Piston
4. Piston Seal
5. Spring Clip
6. Stop Light Switch
7. Brake Pads
8. Brake Line
9. Bleeder Screw
10. Caliper
11. Rope Guide
WARNING
The rider's safety depends on cor-
rect installation. Follow proce-
dures carefully.
Refer to the exploded view above while performing the following steps.
1. Remove bracket bolts.
2. Disconnect brake line. Drain brake fluid into appropriate container and dispose of properly.
3. Disassemble on a clean bench.
4. Open bleeder screw and drain brake fluid from caliper assembly into appropriate container. Dispose of
properly.
CAUTION:
Protect eyes from brake fluid at all times.
5. Slide brake assembly out of bracket and remove old pads and clips.
6. Place caliper on bench with piston down.
7. Remove piston from caliper using a caliper piston pliers (commercially available) or by covering the piston with
a shop cloth and applying compressed air to the hydraulic inlet port.
CAUTION:
Use only enough air to remove piston. Too much pressure may damage piston or bore.
8. Using a small wooden or plastic stick, work piston seal out from its groove in the piston bore.
CAUTION:
To avoid scratching bore or burring edge of seal groove, do not use a metal tool such as a screwdriver.
9. Discard old seal.
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