Polaris 2005 SPORTSMAN 400, Servise Manual

Page: 255 / 312

BRAKES
9.19
REAR CALIPER
REMOVAL/INSPECTION
1. Clean caliper area before removal.
2. Using a flare nut wrench, remove hand brake
(inner) and auxiliary brake (outer) lines. Place a
container to catch brake fluid draining from brake
lines.
3. Remove the two caliper mounting bolts and the
caliper.
4. Remove the slide bolt snap rings (A), the slide
pins(B), the bracket pad (C), and the brake pads
(D).
A
Caliper
B
C
D
5. Remove the anvil bolts and separate caliper
halves and remove pistons with piston pliers.
Seal
Piston & O--rings
Caliper
Anvil Bolts
6. Remove seals and O-rings. Clean the O-ring
grooves.
7. Clean disc, caliper body, and pistons with brake
cleaner or alcohol.
8. Remove the slide bolt bushings. Inspect the
bushings and O--rings and replace if necessary.
Bushing
O--ring
9. Measure the inside diameter of the rear caliper.
The caliper body is a 2--step piston. The rear step
is measured as well as the outside step.