9916575 1998-1999 Big Boss 6x6 Service Manual Chapter
Contents
1. Gp POLARIS BRAKES MASTER CYLINDER INSTALLATION 1 Install master cylinder on handlebars Torque mounting bolts to 55 in Ibs 6 Nm NOTE To speed up the brake bleeding procedure the master cylinder can be purged of air before the brake line is installed Fill reservoir with DOT3 brake fluid and pump lever slowly two to three times with finger over the outlet end 2 Place new sealing washers on each side of banjo line and torque banjo bolt to specification Torque to 15 ft Ibs 21 Nm om o A Banjo Bolt Master Cylinder Mounting Bolt Torque 55 in Ibs 6 Nm Brake Line Banjo Bolt Torque 15 ft Ibs 21 Nm Sealing Washers AN Brake Line 3 Fill reservoir with DOT 3 fluid 4 Follow bleeding procedure on pages 9 5 9 6 Check all connections for leaks and repair if necessary Polaris DOT 3 Brake Fluid PN 2870990 BRAKES FRONT PAD REMOVAL 1 Elevate and support front of machine CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 2 Remove the front wheel Loosen pad adjuster screw 2 3 turns 3 Remove caliper from mounting bracket 4 Push caliper piston into caliper bore slowly using a C clamp or locking pliers with pads installed NOTE Brake fluid will be forced through compensating port into master cylinder fluid reservoir when piston is pushed back into caliper Remove exc2. NOTE If new brake pads are installed it is recommended that a burnishing procedure be performed to extend pad ser vice life and reduce noise Start machine and slowly in crease speed to 30 mph Gradually apply brakes to stop ma chine Repeat procedure 10 times Gp POLARIS BRAKES 9 19 BRAKES FRONT BRAKE CALIPER EXPLODED VIEW Adjuster Screw Square Caliper Mount 9 20 BRAKES REAR BRAKE CALIPER DISASSEMBLY 10 11 Make alignment marks on stationary ramp and caliper housing as shown in IIl 1 Remove cotter pin and washer from actuator rod at brake arm Remove stationary ramp attaching screws C Remove ramp assembly D It is not necessary to remove rear brake arm unless brake arm or piston pin are being replaced NOTE To remove rear brake arm or pin turn the adjuster screw clockwise with a 3 16 Allen wrench until the piston pin falls out To remove brake arm insert a deep well socket into moveable cam to hold lock nut while backing out the adjuster screw Apply downward pressure on brake pads directly over retaining pin releasing pin pressure Shake pin out of caliper or use a needle nose pliers to remove pin NOTE If pins are corroded it may be necessary to spray penetrating oil on pins Remove pins and brake pads Insert a drift punch in piston pin hole and tap with a soft face hammer This will drive out the caliper piston See ll 3 By hand walk caliper pisto
3. 1 186 1 1875 30 13 30 16 mm Service Limit 1 1855 30 11 mm 3 Inspect the brake disc and pads as outlined for brake pad replacement this section See pages 9 12 and 9 14 Gp POLARIS BRAKES 9 17 BRAKES FRONT CALIPER ASSEMBLY 1 Install new O rings in the caliper body Be sure groove is clean and free of residue or brakes may drag 2 Coat piston with clean DOT 3 brake fluid Install piston 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 Polaris Premium All Season Grease and install the rubber dust seal boots Polaris Premium All Season Grease PN 2871423 4 Compress the mounting bracket and make sure the dust seals are fully seated Install the pads as shown on page 9 13 Clean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt oil or grease 9 18 Gp POLARIS FRONT CALIPER INSTALLATION 1 Install caliper on hub strut and torque mounting bolts Front Caliper Mounting Bolt Torque 18 ft Ibs 25 Nm 2 Install brake line and tighten securely with a line wrench 3 Install the adjuster screw and turn until stationary pad contacts disc then back off 1 2 turn 4 Follow brake bleeding procedure outlined on pages 9 5 9 6 5 Install wheels and torque wheel nuts to specification Front Wheel Nut Torque 15 ft Ibs 21 Nm
4. Lubricate new seals B with brake fluid and install into caliper 3 If piston pin or axillary brake arm were removed lubricate all sliding surfaces of stationary and moveable brake ramps with a thin coat of Polaris high temp grease 4 Align mark of stationary and moveable cam so long side of lobe is in the up position and just to the right Polaris High Temp Grease of mark on stationary Alignment marks must be matched and cam positioned correctly as there PN 2870616 are six possible combinations 5 Reassemble adjuster screw through arm and moveable cam Install washer on screw inside of cam Reinstall lock nut and tighten until seated then turn an additional 1 2 turn tighter Stationary 6 Using a new gasket assemble ramp to brake Suggested area LE Ramp caliper NOTE Align marks of stationary and to make align caliper made in step 1 Torque bolts to 5 6 ft Ibs ment marks 7 Hold caliper so that the brake line fitting hole can be covered with your finger Close bleeder fitting and Long Side 4 of Moveable add approximately 1 4 ounce of brake fluid to Ramp Lobe piston bore CAUTION Brake fluid will cause damage to painted surfaces Wipe up any spills at once 8 Lubricate piston with brake fluid and install in caliper piston bore flat beveled end first 9 Compress piston until seated in caliper and wipe off excess brake fluid from piston area 10 Attach brake line to caliper assembly and tighten fitting wit
5. fitting NOTE Fluid may be forced from compensation port B when brake lever is pumped Place diaphragm C in reservoir to prevent spills Do not install cover BRAKES BRAKE BLEEDING FLUID CHANGE CONT 7 Slowly pump brake lever D until pressure builds and holds 8 While maintaining lever pressure open bleeder screw Close bleeder screw and release brake lever NOTE Do not release lever before bleeder screw is tight or air may be drawn into caliper 9 Repeat procedure until clean fluid appears in bleeder hose and all air has been purged Add fluid as necessary to maintain level in reservoir CAUTION Maintain at least 1 2 1 27 cm of brake fluid in the reser voir to prevent air from entering the master cylinder 10 Tighten bleeder screw securely and remove bleeder hose 11 Repeat procedure steps 5 9 for the remaining caliper s 12 Add brake fluid to the proper level Master Cylinder Fluid Level Between MIN and MAX lines 13 Install diaphragm cover and screws Tighten screws to specification Reservoir Cover Torque 45 in Ibs 5 Nm 14 Field test machine at low speed before putting into service Check for proper braking action and lever reserve With lever firmly applied lever reserve should be no less than 1 2 1 3 cm from handlebar 15 Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasion Replace hose if wear or abrasi
6. to drag due to fluid expansion Located within the master cylinder is the compensating port C which is opened and closed by the master cylinder piston assembly The port is open when the lever is released and the master cylinder piston is outward As the temperature within the hydraulic system changes this port compensates for fluid expansion heated fluid or con traction cooled fluid During system service be sure this port is open Due to the high temperatures created within the system during heavy braking it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion Never overfill the reservoir Fill to 1 4 5 16 64 80 cm from top of the cylinder This system also incorporates a diaphragm E as part of the cover gasket and a vent port F located between the gasket and the cover The combination diaphragm and vent allow for the air above the fluid to equalize pres sure as the fluid expands or contracts Make sure the vent is open and allowed to function If the reservoir is over filled or the diaphragm vent is plugged the expanding fluid may build pressure in the brake system leading to brake failure When servicing Polaris ATV brake systems use only Polaris DOT 3 high temperature brake fluid PN 2870990 Polaris brake fluid is sold in 5 5 oz bottles WARNING Once a bottle is opened use what is necessary and discard the rest in accordance with local laws Do not store or use a par
7. 3 Brake Fluid PN 2870990 Master Cylinder Fluid Level 1 4 5 16 6 8 mm below top of master cylinder 8 Refer to brake bleeding instructions in this chapter and bleed system 9 Field test unit for proper braking action before putting into service Inspect for fluid leaks and firm brakes Make sure the brake is not dragging when lever pedal is released If the brake drags re check assembly installation and adjustment 10 Machine should be stopped at least ten 10 times from at least 30 miles per hour using the auxiliary brake pedal only BRAKES REAR BRAKE CALIPER Torque NG Ar Seat then tighten an additional 1 2 tum See step 5 page 9 22 Z 7 Ng Auxiliar N ag a gt Ramp Moveable KS 2 amp Stationary gor Auxiliary Torque Caliper Arm 5 6 ft Ibs Detail A 69 83 Kg m 9 24 REAR BRAKE CALIPER MOUNTING Auxiliary Caliper Torque 12 ft Ibs 1 65 Kg m BRAKES 9 25 BRAKES TROUBLESHOOTING Brakes Squeal e Dirty contaminated friction pads e Improper alignment e Worn disc e Worn disc splines Poor Brake Performance Airin system e Water in system brake fluid contaminated e Caliper disc misaligned e Caliper dirty or damaged e Brake line damaged or lining ruptured e Worn disc and or friction pads e Incorrectly adjusted lever Incorrectly adjusted stationary pad e Worn or damaged master cylinder or components e Improper clearance between leve
8. CHAPTER 9 BRAKES Specifications Torques 9 1 Brake System Service Notes 9 2 Brake Pad Kits u 2 een eek 9 2 Brake Noise Troubleshooting 9 3 Hydraulic Brake System Operation 9 4 Fluid Replacement Bleeding Procedure 9 5 9 6 Master Cylinder Disassembly 9 7 9 8 Master Cylinder Inspection 9 9 Master Cylinder Assembly 9 9 9 10 Master Cylinder Installation 9 11 Front Pad Removal 9 12 Front Pad Assembly 9 13 9 14 Front Disc Inspection 9 14 Front Disc Removal Replacement 9 15 Front Caliper Removal 9 16 Front Caliper Disassembly 9 16 9 17 Front Caliper Inspection 9 17 Front Caliper Assembly 9 18 Front Caliper Installation 9 19 Front Caliper Exploded View 9 20 Rear Brake Caliper Disassembly 9 21 Rear Brake Caliper Assembly 9 22 Rear Brake Caliper Installation 9 23 Rear Brake Caliper Exploded View 9 24 Rear Brake Caliper Mounting 9 25 Troubleshooting 9 26 BRAKE
9. S SPECIFICATIONS Front Brake Caliper Brake Pad Thickness 275 7 0mm 150 3 81mm Brake Disc Thickness 150 164 3 810 4 166mm 140 3 556mm Brake Disc Thickness Variance Between 002 051mm Measurements Brake Disc Runout 020 50mm Rear Brake Caliper Brake Pad Thickness 38 9 67mm 150 3 81mm Brake Disc Thickness 177 187 4 496 4 750mm 167 4 242mm Brake Disc Thickness Variance Between 002 051mm Measurements Brake Disc Runout 010 25mm TORQUE SPECIFICATIONS Torque ft Ibs except where noted Master Cylinder Mounting Bolts 55 in lbs Master Cylinder Reservoir 445 in Ibs 5 0 Cover Bolt BRAKES BRAKE SYSTEM SERVICE NOTES Disc brake systems are light weight low maintenance and perform well in the conditions ATVs routinely en counter There are a few things to remember when replacing disc brake pads or performing brake system ser vice to ensure proper system function and maximum pad service life e Optional pads are available to suit conditions in your area Select a pad to fit riding style and environment e Do not over fill the master cylinder fluid reservoirs e Make sure the brake levers return freely and completely Adjust stop pin on front caliper after pad service e Check and adjust master cylinder reservoir fluid levels after pad service e Make sure atmospheric vent on reservoirs are unobstructed Test for brake drag after a
10. commended that a burnishing procedure be performed after installation of new brake pads to extend service life and reduce noise Start machine and slowly increase speed to 30 mph Gradually apply brakes to stop machine Repeat procedure 10 times Front Wheel Nut Torque 15 ft Ibs 21 Nm FRONT DISC INSPECTION 1 Visually inspect the brake disc for nicks scratches or damage 2 Measure the disc thickness at 8 different points around the pad contact surface using a 0 1 micrometer Replace disc if worn beyond service limit Brake Disc Thickness New 150 164 3 810 4 166 mm Service Limit 140 3 556 mm Brake Disc Thickness Variance Service Limit 002 051 mm difference between measurements 3 Mount dial indicator as shown to measure disc runout Slowly rotate the disc and read total runout on the dial indicator Replace the disc if runout exceeds specifications Brake Disc Runout Service Limit 020 50 mm 9 14 Gp POLARIS FRONT BRAKE DISC REMOVAL REPLACEMENT 4 5 CAUTION Always use new brake disc mounting bolts Apply heat to the hub in the area of the brake disc mounting bolts to soften the bolt locking agent Remove bolts and disc Clean mating surface of disc and hub Install disc on hub Install new bolts and tighten to specified torque The bolts have a pre applied locking agent which is 18 ft Ibs 25 Nm destroyed upon removal Use new bolts
11. ess fluid from reservoir as required 5 Push mounting bracket inward and slip outer brake pad past edge Remove inner pad 6 Measure the thickness of the pad material Replace pads if worn beyond the service limit Front Brake Pad Thickness New 275 7 0 mm Service Limit 150 3 81 mm 9 12 Measure Thickness Gp POLARIS FRONT PAD ASSEMBLY 1 Lubricate mounting bracket pins with a light film of Polaris Premium All Season Grease and install rubber dust boots Polaris Premium All Season Grease PN 2871423 Compress mounting bracket and make sure dust boots are fully seated Install pads with friction material facing each other Be sure pads and disc are free of dirt or grease 3 Install caliper on hub strut and torque mounting bolts Front Caliper Mounting Bolts Torque 18 ft Ibs 25 Nm 4 Slowly pump the brake lever until pressure has been built up Maintain at least 1 2 12 7 mm of brake fluid in the reservoir to prevent air from entering the brake system PAD ADJUSTMENT 5 Install the adjuster screw and turn clockwise until stationary pad contacts disc then back off 1 2 turn counterclockwise 6 Besure fluid level in reservoir is between MIN and MAX lines and install reservoir cap Master Cylinder Fluid Between MIN and MAX lines Gp POLARIS BRAKES 9 13 BRAKES FRONT PAD ASSEMBLY CONT 7 Install wheels and torque wheel nuts 8 It is re
12. h a flare nut wrench CAUTION Brake fluid will cause damage to painted surfaces Wipe up any spills at once 11 Reinstall spring plate brake pads and pad pins to caliper 12 Pump the handle 10 to 15 times to purge any fluid which may have accumulated between the seals during assembly 13 Thoroughly wipe the piston and caliper dry 14 Pressurize the brake system for approximately one minute NOTE The parking brake may be used to hold the pressure 15 Check for low pressure leaks by lightly pumping the handle 5 to 10 times 16 Compress piston into caliper until seated NOTE The brake pads will need to be spread enough to accept the brake disc when reinstalling the caliper as sembly BRAKES REAR BRAKE CALIPER INSTALLATION 1 Reinstall caliper assembly onto brake disc 2 Install upper and lower caliper bolts lock washers and flat washers G to caliper shield H and secure caliper assembly to its mounting 3 Torque caliper mount bolts to specification 4 Install brake line to specified torque 5 Reinstall the middle chain guard D with rear most bolt lock washer flat washer A and spacer B Bolt the forward end of chain guard to the mounting brackets with hardware C 6 Reinstall right front and rear mud flap bolt in footrest 7 Refill master cylinder with DOT 3 brake fluid and Caper Mount Bol torque reinstall cover and diaphragm 10 12 ft Ibs 1 4 1 7 kg m Polaris DOT
13. n proper diaphragm movement C Moveable Brake Pad G The Polaris brake system consists of the following components or assemblies brake lever master cylinder hy draulic hose brake calipers slave cylinder brake pads and brake discs which are secured to the drive line When the hand activated brake lever A is applied it contacts a piston B within the master cylinder As the mas ter cylinder piston moves inward it closes a small opening compensating port C within the cylinder and starts to build pressure within the brake system As the pressure within the system is increased the piston D located in the brake caliper moves outward and applies pressure to the moveable brake pad This pad contacts the brake disc and moves the caliper in its floating bracket pulling the stationary side pad into the brake disc The resulting friction reduces brake disc and vehicle speed As the lever pressure is increased the braking affect is also in creased The friction applied to the brake pads will cause the pads to wear As these pads wear the piston within the caliper moves further outward and becomes self adjusting Fluid from the reservoir fills the additional area created when the caliper piston moves outward Brake fluid level is critical to proper system operation Too little fluid will allow air to enter the system and cause the brakes to feel spongy Too much fluid could cause brakes
14. n back and forth until it can be pulled out of caliper or remove with a caliper piston pliers internal expanding Straighten a large paper clip and form a small hook on one end Polish the end of the clip so there are no sharp edges CAUTION Extreme care must be used to avoid scratching the cylinder bore seal ring groove surfaces Position clip in cylinder bore With a pushing twisting action remove large inside seal and small outer dust seal and two small O ring seals from brake caliper pin hole Important Flush cylinder bore with brake fluid and clean with compressed air Inspection 1 2 Inspect cylinder bore for scoring pitting or corrosion A corroded or scored casting should be replaced light scores and stains may be removed by polishing Polish any discolored or stained area with crocus cloth only CAUTION If you are cleaning the cylinder bore use finger pressure and rotate the cloth Do not slide the cloth in or out of bore while applying pressure as scratches may result Do not use any other type of abrasive or abrasive cloth Inspect piston Gp POLARIS Adjuster Screw Suggested area to make align Auxiliary ment marks Brake Arm ll 1 lll 2 Insert Drift Punch lll 3 Ill 4 9 21 BRAKES REAR BRAKE CALIPER ASSEMBLY NOTE Clean and inspect all components before reas sembling 1 Lubricate new O rings A with brake fluid and install into caliper pin bore 2
15. not reduce the occurrence of brake noise Permatex Disc Brake Quiet available from most auto parts stores can be applied to the back of the pads Follow directions on the package This will keep pads in contact with caliper piston s to reduce the chance of squeaks caused by dirt or dust Brake Noise Troubleshooting Possible Cause Dirt dust or imbedded material on pads or disc Spray disc and pads with CRC Brakeleen or an equivalent non flammable aerosol brake cleaner Re move pads and or disc hub to clean imbedded material from disc or pads Pad s dragging on disc noise or premature pad wear Improper adjustment Adiust pad stop front calipers Insufficient lever or pedal clearance Check position of controls amp switches Master cylinder reservoir overfilled Set to proper level Master cylinder compensating port restricted Clean compensating port Master cylinder piston not returning completely Inspect Repair as necessary Caliper piston s not returning Clean piston s seal Operator error riding the brake park brake Educate operator applied Noise is from other source chain axle hub disc or wheel other sources Inspect and repair as necessary Wrong pad for conditions Change to a softer or harder pad BRAKES HYDRAULIC BRAKE SYSTEM OPERATION Typical Hydraulic Brake System Compensating port compensates E for temperature changes by allowing fluid back to master cylinder EY Must be clear to allow pO a n
16. ny brake system service and investigate cause if brake drag is evident e Make sure caliper moves freely on guide pins Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely e Perform a brake burnishing procedure after installing new pads to maximize service life BRAKE PAD KITS NOTE Brake pad part numbers are stamped on the back of the pad for identification purposes This part number cannot be ordered it is included in the chart for reference only Part numbers on the following chart may change or supercede to a new number an refer to the current parts manual for pan numbers PartNo Type Description Application FRONT BRAKE PAD KITS 2201149 2201149 Kit Soft Frontbrake pad kit Contains 4pads PN brake pad kit Contains 4 pads PN For dry dusty conditions dry dusty conditions 1930731 2200465 Kit Front brake pad kit Contains 4 pads PN Production pad For average use 1930815 2200901 Kit Severe Front brake pad kit Contains 4 pads PN For muddy conditions Duty 1930811 REAR BRAKE PAD KITS 2201150 Kit Rear brake pad kit For dry dusty conditions 2200464 Kit Rear brake pad kit Production pad For average use 2200899 Kit Rear brake pad kit For muddy conditions BRAKES BRAKE NOISE TROUBLESHOOTING Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise squeal caused by vibration If cleaning does
17. on is found BRAKES MASTER CYLINDER DISASSEMBLY 1 Clean master cylinder and reservoir assembly Make sure you have a clean work area to disassemble brake components 2 Place a shop towel under brake line connection at master cylinder Loosen banjo bolt remove bolt and sealing washers CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces 3 Remove master cylinder from handlebars Banjo Bolt Master Cylinder Piston Assy I 4 Remove cover and diaphragm from master cylinder and dispose of the fluid properly 5 Be sure vents in cover are clean and unobstructed 6 Remove brake lever BRAKES MASTER CYLINDER DISASSEMBLY CONT 7 Remove reservoir screws and reservoir Reservoir Bolts 8 Inspectreservoir seal and replace if worn or damaged Clean surfaces of the reservoir and master cylinder body Be sure compensating port A and supply port B are clean before reassembly 9 Remove outer dust seal Be ready to catch piston assembly NOTE The return spring may force piston out when dust seal has been removed 10 Remove piston assembly and return spring from master cylinder Replace piston assembly and spring Outer Dust Seal BRAKES MASTER CYLINDER INSPECTION 1 Clean the master cylinder assembly with clean Dot 3 brake fluid brake parts cleaner or denatured alcohol Dry thoroughly Inspec
18. r and switch Lever Vibration Disc damaged Disc worn runout or thickness variance exceeds service limit Caliper Overheats Brakes Drag e Compensating port plugged Pad clearance set incorrectly Auxiliary brake pedal incorrectly adjusted Brake lever or pedal binding or unable to return fully e Parking brake left on Residue build up under caliper seals Operator riding brakes Brakes Lock Alignment of caliper to disc 9 26 Gp POLARIS
19. t the bore for nicks scratches or wear Replace if damage is evident or if worn 2 Inspect parking brake for wear If teeth or locking cam are worn replace lever MASTER CYLINDER ASSEMBLY 1 Install new primary and secondary seals on the piston WA u Dust Seal Primary Seal Secondary Seal Return Spring 2 Select the appropriate master cylinder piston installation tool and insert into master cylinder bore Type IV Master Cylinder Hand Brake 750 19mm Installation Tool 2200879 BRAKES MASTER CYLINDER ASSEMBLY CONT 3 Dip pistonin clean DOT 3 brake fluid attach spring to piston and install assembly into installation tool CAUTION Do not attempt to install the piston without the required installation tool Do not allow the lip of the seals to turn in side out or fold 4 Push the piston assembly through the installation tool using the plunger handle Continue pushing until plunger is solid against installation tool 5 Hold piston assembly inward while removing both tools Install a new dust seal Be sure dust seal is completely seated in the groove NOTE The piston assembly should move freely in the bore and spring back against the seal when released 6 Install reservoir with new seal Be careful to install and torque screws evenly 7 Apply a light film of grease to the lever bolt Install lever and tighten bolt securely 8 Install parking brake lever assembly 9 10
20. tial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury BRAKES FLUID REPLACEMENT BLEEDING PROCEDURE NOTE When bleeding the brakes or replacing the fluid always start with the caliper farthest from the master cylinder CAUTION Always wear safety glasses CAUTION Brake fluid will damage finished surfaces Do not allow brake fluid to come in contact with finished surfaces BRAKE BLEEDING FLUID CHANGE This procedure should be used to change fluid or bleed brakes during regular maintenance 1 Clean reservoir cover thoroughly 2 Remove screws cover and diaphragm C from reservoir 3 Inspect vent slots A in cover and remove any debris or blockage 4 If changing fluid remove old fluid from reservoir with a Mity Vac pump or similar tool NOTE Do not remove brake lever when reservoir fluid level is low Mity Vac PN 2870975 5 Add brake fluid to the upper level mark on reservoir Polaris DOT 3 Brake Fluid PN 2870990 6 Begin bleeding procedure with the caliper that is farthest from the master cylinder Install a box end wrench on caliper bleeder screw Attach a clean clear hose to fitting and place the other end in a clean container Be sure the hose fits tightly on
21. with pre applied locking agent Front Brake Disc Mounting Bolt Torgue 18 ft Ibs 25 Nm Gp POLARIS BRAKES 9 15 BRAKES FRONT CALIPER REMOVAL CAUTION Use care when supporting vehicle so that it does not tip or fall Severe injury may occur if machine tips or falls 1 Remove brake pads See page 9 12 2 Using a line wrench loosen and remove brake line to caliper Place a container under caliper to catch fluid draining from brake line 3 Remove brake caliper and drain fluid into container FRONT CALIPER DISASSEMBLY 1 Remove brake pad adjuster screw 2 Push upper pad retainer pin inward and slip brake pads past edge 3 Remove mounting bracket pin assembly and dust boot Remove l Mounting Bracket 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 Replace if damage is evident or if worn beyond service limit Front Caliper Piston Bore I D Std 1 191 1 192 30 25 30 28 mm Service Limit 1 193 30 30 mm 2 Inspect piston for nicks scratches wear or damage Measure diameter and replace if damaged or worn beyond service limit Front Caliper Piston O D Std
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