10
9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual
© Copyright Polaris Industries Inc.
10.25
REAR CALIPER DISASSEMBLY
1. Remove brake pad adjustment set screw
o
.
2. Push upper pad retainer pin inward and slip brake
pads
q
past the edge and remove from the caliper.
3. Remove mount bracket
w
and dust boots (
y
and
u
).
4. Using a hammer and a small punch, remove the
pistons
t
from the caliper body
i
. Remove the
square O-rings (
r
and
e
) from the caliper body
i
.
5. Clean the caliper body, piston, and retaining bracket
a
with brake cleaner or alcohol.
NOTICE
Be sure to clean caliper body seal grooves.
REAR 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.
MEASUREMENT
Rear Caliper Piston Bore I.D.:
Standard: 1.505″ (38.23 mm)
Service Limit: 1.507″ (38.28 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
MEASUREMENT
Rear Caliper Piston O.D.:
Standard: 1.500″ (38.10 mm)
Service Limit: 1.498″ (38.05 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
BRAKE SYSTEM
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