2005 Polaris Sportsman 400/500 Service Manual, Page 250Get this manual
BRAKES 5Clean the caliper body, piston, and retaining bracket with brake cleaner or alcoholNOTE: Be sure to clean seal grooves in caliper body2Inspect piston for nicks, scratches, wear or damageMeasure diameter and replace if damaged or worn beyond service limit
Clean Components
FRONT CALIPER INSPECTION
1Inspect caliper body for nicks, scratches or wearMeasure bore size and compare to specificationsReplace if damage is evident or if worn beyond service limitFront Caliper Piston Bore I.DStd1.188 (30.2 mm) Service Limit 1.193 (30.30 mm)