Caliper Disassembly; Caliper Inspection - Polaris 2008 RZR Service Manual

Caliper Disassembly

1. Remove brake pad adjustment set screw (K).
2. Push upper pad retainer pin inward and slip brake pads past
the edge and remove from the caliper.
3. Remove mounting bracket (B) and dust boots (G) and (H).
D
K
H
E
F
C
4. Using a hammer and a small punch, remove the piston (C)
from the caliper body (D). Then remove the square O-rings
(E) and (F) from the caliper body (D).
5. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper
body.
G
Pads
B
Clean Components

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.
Rear Caliper Piston Bore I.D.
Standard: 1.191" (30.25 mm)
Service Limit: 1.192" (30.28 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.
Standard: 1.1875" (30.16 mm)
Service Limit: 1.186" (30.12 mm)
3. Inspect the brake disc and pads as outlined in this chapter.
BRAKES
= In. / mm.
= In. / mm.
9.17
9