Polaris RANGER XP 700 4X4 Service Manual page 281

BRAKES
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.
Rear Caliper Piston Bore I.D.
Std. 1.2550" (3.227 mm)
Service Limit 1.256" (31.902 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.
Rear Caliper piston O.D.
Std. 1.250" (31.75 mm)
Service Limit 1.2495" (31.737 mm)
3. Inspect the brake disc and pads as outlined for brake pad
replacement in this chapter.
9.24
Caliper Assembly
1. Install new square O-rings (A) in the caliper body. Be sure
that the grooves are clean and free of residue or brakes may
drag.
2. Coat the piston with clean Polaris DOT 4 Brake Fluid
(P/N 2872189). Install piston (B) 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 with Polaris Premium
All Season Grease, and install the rubber dust seal boots.
Polaris Premium All Season Grease
(PN 2871423)
4. Compress the mounting bracket and make sure the dust
seals 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.
A
B
4