Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 348 / 432

9.18
BRAKES
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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 section. See “BRAKE PAD
INSPECTION” earlier in this chapter.
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.
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 disc brake
caliper lube, and install the rubber dust seal boots.
= In. / mm.
Front Caliper Piston Bore I.D.:
Service Limit: 1.193” (30.30 mm)
A
B
C
D