Table of Contents
BRAKE SYSTEM
FRONT CALIPER DISASSEMBLY /
INSPECTION
1. Remove the mount bracket assembly
w
boots
.
2. Thoroughly clean the caliper before disassembly and
prepare a clean work area for disassembly.
3. Use a commercially available caliper piston pliers to
e
extract the pistons
IMPORTANT
Do not remove the caliper pistons with a standard
pliers. The piston sealing surface will become damaged
if a standard pliers is used.
9.16
q
and dust
from the caliper
4. Once the pistons are removed, use a pick to carefully
r
remove the o-rings
be replaced during caliper service.
5. Clean the caliper body, pistons, and retaining bracket
with brake cleaner or alcohol.
Be sure to clean all the seal grooves in the caliper body.
6. Inspect caliper body for nicks, scratches, pitting or
wear.
7. Measure bore size and compare to specifications.
Replace if damaged or worn beyond service limit.
MEASUREMENT
Front Caliper Piston Bore I.D.:
Large Bore: 1.375" (34.93 mm)
Medium Bore: 1.188" (30.18 mm)
Small Bore: 1.000" (25.4 mm)
8. Inspect piston for nicks, scratches, pitting or wear.
9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
from the caliper. O-rings should
NOTE
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