Auxiliary Brake Caliper Service (Mechanical) Disassembly - Polaris Trail Blazer Service Manual

Disassembly
1. Make alignment marks on stationary ramp and caliper
housing as shown in Ill.1.
2. Remove cotter pin and washer from actuator rod at
brake arm.
3. Remove stationary ramp attaching screws (C).
4. Remove ramp assembly (D). It is not necessary to
remove auxiliary brake arm unless brake arm or piston
pin are being replaced. NOTE: To remove auxiliary
brake arm or pin, turn the adjuster screw clockwise with
a 3/16" Allen wrench until the piston pin falls out. To
remove brake arm, insert a deep well socket into
moveable cam to hold lock nut while backing out the
adjuster screw.
5. Apply downward pressure on brake pads directly over
retaining pin, releasing pin pressure. Shake pin out of
caliper or use a needle nose pliers to remove pin.
NOTE: If pins are corroded it may be necessary to
spray penetrating oil on pins.
6. Remove pins and brake pads.
7. Insert a drift punch in piston pin hole and tap with a soft
face hammer. This will drive out the caliper piston. See
Ill. 3.
8. By hand, walk caliper piston back and forth until it can
be pulled out of caliper or remove with a caliper piston
pliers (internal expanding).
9. Straighten a large paper clip and form a small hook on
one end. Polish the end of the clip so there are no sharp
edges. CAUTION: Extreme care must be used to
avoid scratching the cylinder bore seal ring groove
surfaces.
10. Position clip in cylinder bore. With a pushing, twisting
action remove large inside seal and small outer dust
seal and two small O-ring seals from brake caliper pin
hole.
11. Important: Flush cylinder bore with brake fluid and
clean with compressed air.
Inspection
1. Inspect cylinder bore for scoring, pitting, or corrosion. A
corroded or scored casting should be replaced; light
scores and stains may be removed by polishing. Polish
any discolored or stained area with crocus cloth only.
CAUTION: If you are cleaning the cylinder bore, use
finger pressure and rotate the cloth. Do not slide the
cloth in or out of bore while applying pressure as
scratches may result. Do not use any other type of
abrasive or abrasive cloth.
2. Inspect piston.
Polaris Sales Inc.
Auxiliary Brake Caliper Service (Mechanical)
Suggested area
to make align-
ment marks
Ill. 1
Ill. 2
Insert Drift
Punch
Ill. 3
Ill. 4
9.33
BRAKES
D
Adjuster
Screw
Auxiliary
C
Brake
Arm
4/99