2003 Bombardier Outlander 400 Factory Service Manual, Page 304Get this manual
Section 09 BRAKES Subsection 02 (HYDRAULIC BRAKES)
CALIPER
Removal
Loosen wheel nutsRaise vehicle and support it securelyRemove wheel(s)Drain brake systemRemove banjo bolt no15 with sealing washers no16 and detach brake hose from caliperCatch spilled fluid with ragAttach the brake hose in position to prevent the fluid from flowing outUnscrew bolts no30 retaining caliper on its support and remove caliperWARNING
Do not use high pressure air or bring nozzle too close to inletRemove piston sealCAUTION: Be careful not to damage piston sliding surfaceClean piston grooves, caliper cylinder and piston with clean brake fluidClean slide pins with brake cleaner and rag
Inspection
If boots no33 are deteriorated or hard, replace with new onesCheck caliper cylinder for scratches, rust or other damagesIf so, replace caliperCheck piston for scratches, rust or other damagesIf so, replace piston
Assembly
Coat piston seal with clean brake fluid and install it into piston grooves in caliperCoat piston with clean brake fluid and install into cylinder with the closing toward caliper bodyApply silicone grease into sliding bores and install slide pinsNOTE: Make sure that rubber boots are correctly installed in slide pins groovesInstall pad spring, caliper bracket and pads