Caliper; Caliper Removal; Caliper Replacement; Brake Pad Replacement - Polaris 2007 Two Stroke Service Manual

CALIPER

3
1
5
Caliper

Caliper Removal

1. Remove the two caliper bolts that hold the caliper to the
chaincase.
2. Remove the caliper from the brake disc.

Caliper Replacement

The only serviceable item in the brake caliper is the brake pads,
piston and seals. If any service is required of the caliper a new
caliper is available.
1. The brake line will need to go in the same orientation as it
was when it is replaced. Note the orientation of the brake
line before removing it.
2. Remove the banjo bolt from the brake line and tie up so that
all the brake fluid does not leak out.
3. On a liquid cooled caliper, you will need to drain the
coolant from the coolant hoses.
4. Remove the two bolts (1) holding the caliper (2) to the
chaincase.
5. Remove the caliper from the chaincase.

Caliper Assembly

1. Replace caliper bolts (1) and torque them to 18-20 ft-lb
(24-27 N-m).
Caliper Bolts: 18-20 ft-lb (24-27 N-m)
2. On a liquid cooled caliper, hook up the coolant lines.
3. Place the brake line on the caliper in the same orientation
as it was before it was removed.
4. Clean the threads of the banjo bolt and the threads in the
caliper.
4
2
= T
FINAL DRIVE/BRAKES
5. Follow Brake Line Replacement. See "Brake Line
Replacement" on page 7.21.
6. Install banjo bolt into the caliper and torque it to 168-216
in-lb (19-24 N-m).
7. Bleed the brakes. See "Brake Fluid Replacement &
Bleeding" on page 7.20.
8. On a liquid cooled caliper you will need to bleed the cooling
system of any trapped air.

Brake Pad Replacement

Brake pads need to be replaced if the total
thickness of the pads and backing are less than
.250" (6.35mm).
1. Remove brake pad retaining pin (3).
2. Remove the brake pads (4).
3. Inspect the brake disc (5) for any wear.
4. Replace brake pads in reverse order of
removal.

Brake Disc Replacement

The brake disc should be replaced if the thickness of the disc is
below .193"(.49cm).
1. Remove the chaincase. See "Chaincase Removal" on
page 7.8.
2. Slide the brake disc from the jackshaft.
3. Check the jackshaft for any damage.
4. Replace the o-ring on the jackshaft
5. Replace the brake disk.
6. Assemble the chaincase.
Brake Pad
.250" (6.35mm)
7
7.23