Rear Caliper Inspection; Rear Caliper Assembly - Polaris RANGER 500 2018 Service Manual

BRAKE SYSTEM

REAR 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
Caliper Piston Bore I.D.:
Std: 1.505" (38.23 mm)
Service Limit: 1.507" (38.28 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
MEASUREMENT
Caliper Piston O.D.:
Std: 1.500" (38.10 mm)
Service Limit: 1.498" (38.05 mm)
3. Inspect the brake disc and pads as outlined for brake
pad replacement in this chapter.
9.32

REAR CALIPER ASSEMBLY

1. Install new square O-rings
sure that the grooves are clean and free of residue or
brakes may drag.
2. Coat the piston with clean DOT 4 Brake Fluid (PN
2872189). Install piston
while pushing inward. Piston should slide in and out
of bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with disc brake
caliper lube, and install the rubber dust seal boots.
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.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
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in the caliper body. Be
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with a twisting motion
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