Front Caliper Removal; Front Caliper Disassembly - Polaris Trail Boss 330 2003 Service Manual

1. Apply heat to the hub in the area of the brake disc
mounting bolts to soften the bolt locking agent.
18 ft. lbs. (25 Nm)
new bolts have
pre-applied
locking agent.
2. Remove bolts and disc.
3. Clean mating surface of disc and hub.
4. Install disc on hub.
5. Install new bolts and tighten to specified torque.
Front Brake Disc Mounting Bolt Torque
18 ft. lbs. (25 Nm)
CAUTION: Always use new brake disc mounting
bolts. The bolts have a pre-applied locking agent
which is destroyed upon removal.

FRONT CALIPER REMOVAL

CAUTION:
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if machine
tips or falls.
1. Remove brake pads. See Page 9.9.
2. Using a line wrench, loosen and remove brake
line to caliper. Place a container under caliper to
catch fluid draining from brake line.
9.12
3. Remove brake caliper and drain fluid into
container. Do not reuse brake fluid.
FRONT CALIPER
DISASSEMBLY
1. Remove brake pad adjuster screw.
2. Push upper pad retainer pin inward and slip brake
pads past edge.
BRAKES