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Polaris SPORTSMAN 400 2003 - Front Caliper Reassembly

Polaris SPORTSMAN 400 2003
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BRAKES
9.15
3. Inspect the brake disc and pads as outlined for
brake pad replacement this section. See Pages
9.10--9.11.
FRONT CALIPER REASSEMBLY
1. Install new O-rings (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes
may drag upon assembly.
A
B
C
2. Coat piston with clean Polaris DOT 3 Brake Fluid
(PN 2870990) (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, and install the
rubber dust seal boots.
Polaris Premium All Season Grease
(PN 2871423)
4. Compress the mounting bracket and make sure
the dust seals are fully seated. Install the pads as
shown on Page 9.10. Clean the disc and pads
with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
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