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Polaris Sportsman 500 Service Manual

Polaris Sportsman 500
381 pages
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BRAKES
9.19
FRONT CALIPER DISASSEMBLY, CONT.
4. Remove piston, dust seal and piston seal.
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.
Replaceifdamageis evidentor ifwornbeyondservice
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 this section. See page 9.16.
Front Caliper Piston Bore I.D.
Std. 1.191-1.192″ (30.25-30.28 mm)
Service Limit 1.193″ (30.30 mm)
Front Caliper Piston O.D.
Std. 1.186-1.1875″ (30.13-30.16 mm)
Service Limit 1.1855″ (30.11 mm)

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Polaris Sportsman 500 Specifications

General IconGeneral
BrandPolaris
ModelSportsman 500
CategoryOffroad Vehicle
LanguageEnglish

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