Polaris 1999 Sportsman 400 Service Manual page 407

BRAKES
46
and to prevent any residual brake fluid from drip-
ping out.
6. If necessary, disassemble, inspect and assemble
the outpu t shaft ca liper as described in this chapter.
Installation
I. Conn
ect both fillings (Figure 45 ) and brake
hoses onto the caliper. Do not tighten at this time.
2. If removed, install the brake pads as described in
this cha pter.
3. Care fully install the caliper assem bly onto the
disc, being careful not to dam age the leadin g edge
of the brake pads.
4 . Install the caliper mounting bolts, lockw ashers
and washers (Figu re 36) and tighten to the torqu e
specificatio ns listed in Table 2
5. Tighten both fillings (Figu re 45) seem ing the
brake hoses to the caliper securely.
6. If the caliper was disassemb led, securely
tighten the Allen bo lt on the back side o f the ca liper
(Figure 44 ).
7. Bleed the brake as described under
Ble edin g the
Syst em
in this chapter.
401
WARN ING
Make sure the bra kes are operating
correctly with [ull hy draulic advan-
tage before operating the vehicle.
If
Ilecessm y.
hleed the brakes
as
de-
scribed in this
chap ter:
Disassembly
NOTE
There are
IlO
new or service limit
specifications
fo r the ca liper assem-
bly. Replacem ent piston seals. dust
seals and piston are available.
I.
Remove the ca liper as described in this chapter.
2. Remove the Allen bolt (Figu re 46) securing the
caliper halves together.
3. Care fully separate the calip er halves and remove
both O-ri ng sea ls from the outboard ca liper haif.
NOTE
If
the pistons were partiallyforced out of
the caliper body during
remov al.
Steps
2-4 may
not
be
necessary.
Ifthe
piston or
caliper bores are corroded
0 1'
vel)' dirty.
a small amount ofcompressed
air
may
be necessary
to completely remove the
pistonsfrom the body bores.
4. Place a piece of soft woo d or folded shop cloth
over the end of the pisto n and the caliper body. Tum
this assembly over with the piston facing down.
WARNIN G
In
the
next
step, the piston may shoot
0111
of
the caliper
body.
Keep allfingers
out oj the way.
J~e(lr
simp gloves lind
II
(JPP~V
air pressure
gradually:
Do
1I0 t
use
high-pressure
air or place the air
hose
nozzle directl y aga inst the brake
hose jillillg inlet ill the caliper body.
Hold the air nozzle
awayfrom
the inlet.
allowing some ofthe air to escape.
5. App ly the air pressure in short spurts to the brake
hose inlet fittiog (F igure 47) and force out the pis-
ton. Use a service station airhose if compressed air
is not available.
6. Withdraw the piston from each ca liper half.
CAU110N
In the following st ep, do not use a
sha rp too l to remo ve the piston sea l