Caliper Inspection; Caliper Assembly - Polaris ACE 900 2017 Service Manual

BRAKE SYSTEM

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
Rear Caliper Piston Bore I.D.
Standard: 1.252-1.254" (31.826-31.852 mm)
Service Limit: 1.255" (31.877 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
MEASUREMENT
Rear Caliper Piston O.D.
Standard: 1.248-1.250" (31.699-31.75 mm)
Service Limit: 1.2475" (31.686 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
9.22

CALIPER ASSEMBLY

1. Install new caliper seals
sure groove is clean and free of residue or brakes
may drag upon assembly.
2. Coat piston with clean Polaris 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
grease 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.
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