Polaris 2012 Sportsman Forest 500 International, Service Manual

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9.27
BRAKES
9
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
8. Remove the slide bolt bushings. Inspect the bushings
and O-rings and replace if necessary.
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.
10. Inspect caliper piston bore for scratches, severe
corrosion, or galling and replace if necessary.
11. Inspect surface of caliper piston for nicks, scratches,
or damage and replace if necessary.
Assembly
1. Install new O-rings in the slide bolt bushing holes. Be
sure O-ring and seal grooves are thoroughly cleaned
of all residue, or piston may bind in bore. Apply brake
fluid to piston seals and install carefully with a twisting
motion to ease assembly until fully seated.
= In. / mm.
Rear Caliper Piston Bore I.D.
Inner Bore Service Limit: .94” (23.88 mm)
Outer Bore Service Limit: 1.5” (38.1 mm)
O-ring
Bushing
.94in. (23.88) mm)
1.5 in. (38.1 mm)
Inspect
Seals