Rear Caliper Removal/Inspection - Polaris SPORTSMAN 600 2003 Service Manual

BRAKES BRAKES
REAR CALIPER
REMOVAL/INSPECTION
1. Clean caliper area before removal.
2. Using a flare nut wrench, remove hand brake
(inner) and auxiliary brake (outer) lines. Place a
container to catch brake fluid draining from brake
lines.
3. Remove the two caliper bolts and the caliper.
4. Remove the slide bolt snap rings (A), the slide
pins(B), the bracket pad (C), and the brake pads
(D).
Caliper
D
A
Remove inner
and outer
brake lines
C
B
5. Remove the anvil bolts and separate caliper
halves and remove pistons with piston pliers.
Seal
Piston & O--rings
6. Remove seals and O-rings. Clean the O-ring
grooves.
7. Clean disc, caliper body, and pistons with brake
cleaner or alcohol.
8. Remove the slide bolt bushings. Inspect the
bushings and O--rings and replace if necessary.
Bushing
9. Inspect caliper piston bore for scratches, severe
corrosion, or galling and replace if necessary.
10. Inspect surface of caliper piston for nicks,
scratches, or damage and replace if necessary.
Caliper
Anvil Bolts
O--ring
Inspect
9.17