Front Caliper Inspection; Front Caliper Assembly - Polaris RANGER 2x4 Manual

5. Clean the caliper body, piston, and retaining
bracket with brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper body.
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. 1.5050-1.5040² (3.227-30.202 mm)
Service Limit 1.5060² (38.252 mm)
2. Inspect piston for nicks, scratches, wear or
damage. Measure diameter and replace if
damaged or worn beyond service limit.
9.14
Front Caliper Piston O.D.
Std. 1.4985-1.5000² (38.062-38.10 mm)
Service Limit 1.4980² (38.049 mm)
3. Inspect the brake disc and pads as outlined for
brake pad replacement this section. See page
9.11--9.12.

FRONT CALIPER ASSEMBLY

1. Install new O-rings in the caliper body. Be sure
that the grooves are clean and free of residue or
brakes may drag.
2. Coat the piston with clean DOT 3 Brake Fluid (PN
2870990) or DOT 4 Brake Fluid. Install piston
with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly,
with light resistance.
BRAKES