Inspection; Reassembly - Polaris 2007 SPORTSMAN X2 800 Service Manual

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.
Front Caliper Piston Bore I.D.:
Service Limit: 1.193" (30.30 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.
3. Inspect the brake disc and pads as outlined for brake pad
replacement in this section.
INSPECTION" earlier in this chapter.
= In. / mm.
See "BRAKE PAD

Reassembly

1. Install new caliper seals (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes may drag
upon assembly.
C
D
2. Coat piston with clean Polaris DOT-approved Brake Fluid
(C). Install piston (D) with a twisting motion while pushing
inward. Piston should slide in and out of bore smoothly,
with light resistance.
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
BRAKES
B
A
9
9.15