Front Caliper Disassembly - Polaris 1999 Sportsman 400 Service Manual

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388
b. Remo ve
the speed sensor (B
,
Figu re 15)
from
the
bracket
and
mov
e
the
sensor
out
o
f
the
way.
NOTE
0
11/Y
one holt is
sho wn in
Figure
3.
remo
ve
both bolts.
3. Remove both
bo
lts
and was hers (Figu re
3) se-
curing the brak
e
caliper and
remo ve the ca
liper
from
Ihe
brake
disc.
4
.
Loosen
and
remove Ihe brake
hose
(F igure
16)
from
the rear
o
f
the
ca
liper.
5.
If
necessary,
disassemble,
inspect and
asse
mble
the
front ca
liper as
described
in
this
chapter.
6.
Insta ll
by reversin
g
these
remo
val
steps
while
noting
the
followin g
:
a. Install the
brak
e hose
and fittin
g onta the
backside
of
the
ca
liper
and
light en the
fittin
g
on
ly
finger
-tight
(Figure
17).
b. Ca
re fully
insta
ll
the
caliper
assemb ly
onto
the
disc,
bein
g care
ful not
to damage the leading
edge
of
the brake pads.
e.
Install
the
ca liper mountin g bol
ts
and
tighten
to the torqu e spec ifications
listed in Table
2.
d.
Tighten
the brake hose
and
fittin
g
(Figure
18)
secure
ly.
e.
Bleed Ihe brake
as
described under
Bleeding
the
System
in
this
chapter.
WARNING
Make sure
the
brakes are operating
properly
bef ore riding
the
vehicle.
Disassembly
Re fer to
Figure
l.
I. Rem ove the brake pads as described
in
this
chapter,
2.
Rem
ove
the
front
calipe r
as described
in
this
chapter.
3.
Remove
the
mounting
bracket
from
the
ca
liper
bod y.
NO TE
If/he p
iston was panioltyforced
out of
the caliper bod y
during removal,
Steps
4-6 may
not he necessary .
If
the
piston
or caliper bore is corroded or
vel)'
dirty, a small amount oj compressed
air
may
be necessm y
to comp
letely
re-
mo
ve the piston
fi-0111
the
body
bore.
CHAPTER FOURTEEN
4. Place
a
piece of so
ftwo od or
folded
shop
cloth
over
the
end of the pisto
n
and the caliper
body.
WARNING
In
the
nes t
step,
the piston may
shoot
alit of the
caliper
body
Keep
allfingers
out oft he
way.
Wear
shop
gloves
and
apply air
pressure
gradually.
Do
not
use
high-pressure air
or place
the
air
hose nozzle directly
against
the
brake
hose j
ilting
inlet
ill
the
caliper body:
Hold the
air
nozzle
owayfrom
the inlet,
allowing
some of
the air
to
escape
.

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