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9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual
© Copyright Polaris Inc.
10.23
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Caliper Piston O.D.:
Std: 1.370” (34.80 mm)
Service Limit: 1.368” (34.75 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
FRONT CALIPER ASSEMBLY - CREW
1. Install new O-rings (Item 1) in the caliper body. Be
sure the grooves (Item 2) are clean and free of
residue or brakes may drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons 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.
4. Compress the mounting bracket and make sure the
dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
FRONT CALIPER INSTALLATION - CREW
1. Install caliper and torque mounting bolts to
specification.
TORQUE
Front Caliper Mount Bolt:
46 ft-lbs (62 Nm)
BRAKE SYSTEM
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