Caliper Assembly; Caliper Installation - Polaris Ranger 500 2x4 2007 Service Manual

BRAKES
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.

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.
9.22
A
B
2. Coat the piston with clean DOT 3 Brake Fluid (PN
2870990) or DOT 4 Brake Fluid. 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.

Caliper Installation

1. Install the rear caliper onto the mounting bolts. Torque
mounting bolts to 18 ft.lbs. (24 Nm).
2. Install brake line banjo bolt. Torque banjo bolt to 15 ft.lbs.
(21 Nm).
18 ft. lbs.
(24 Nm)
15 ft. lbs.
(21 Nm)
3. Install the rear wheel and wheel nuts. Carefully lower the
vehicle.