9.16
BRAKES
4. Remove piston (D) and square O-rings (E) from the caliper
body (F). See Figure 9.15.
5. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper
body.
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.
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 chapter.
Caliper Assembly
1. Install new square O-rings (A) in the caliper body. Be sure
that the grooves are clean and free of residue or brakes may
drag.
2. Coat the piston with clean Polaris DOT 4 Brake Fluid
(P/N 2872189). Install piston (B) with a twisting motion
while pushing inward. Piston should slide in and out of bore
smoothly, with light resistance.
Front Caliper Piston Bore I.D.
Std. 1.5050-1.5040” (32.27-30.202 mm)
Service Limit 1.5060” (38.252 mm)
Front Caliper Piston O.D.
Std. 1.4985-1.5000” (38.062 - 38.10 mm)
Service Limit 1.4980” (38.049 mm)
A
B
4
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