BRAKES
9.12
FRONT 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.
Front Caliper Piston Bore I.D.
Std. 1.191-1.192² (30.25-30.28 mm)
Service Limit 1.193² (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 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
D
2. Coat piston with clean Polaris DOT 3 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, 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.
Enfocus Software - Customer Support
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