Caliper Inspection; Caliper Assembly - Polaris Sportsman 850 Service Manual

BRAKE SYSTEM
4. Clean the caliper body, piston, and mounting bracket
with brake cleaner or denatured alcohol.
Be sure to thoroughly clean the seal grooves in the
caliper body.

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.
MEASUREMENT
Front Calipers:
Caliper Bore I.D.
Rear Caliper(s):
Caliper Bore I.D.
General Brake Specifications, page 9.3
9.20
NOTE
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
3. Inspect the brake pad and disc.
MEASUREMENT
Front Calipers:
Caliper Piston O.D.
Rear Caliper(s):
Caliper Piston O.D.
General Brake Specifications, page 9.3

CALIPER ASSEMBLY

1. Install new O-rings in the caliper body. Be sure
grooves are clean or brakes may drag upon
assembly.
2. Coat piston with DOT 4 Brake Fluid. Install piston
with a twisting motion while pushing inward. Piston
should slide in and out of the bore smoothly, with
light resistance.
3. Lubricate the mounting bracket pins with silicone
grease, and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seals are fully seated.