Polaris Brake Caliper Rebuild - Sportsman 850 ATV | Partzilla.com

Buy caliper seals and other parts for your Polaris ATV brake caliper rebuild: bit.ly/polaris-...
Learn how to rebuild the front brake caliper on a Polaris Sportsman 850 ATV. John shows you how to remove and replace the front brake caliper, how to take it apart, and how to rebuild it with new caliper seals, boots and bushings.
Get a look at the front brake caliper diagram: www.partzilla....
Read how to do this job step by step: www.partzilla....
Once you’re finished, you’ll need to refill the system. Find out how to bleed the front brakes here:
• How to Bleed Polaris A...
VIDEO HIGHLIGHTS:
Removing the brake caliper - 0:38
Removing the brake pads - 3:25
Removing the piston - 3:30
Removing old seals - 5:00
Installing new seals - 6:00
Reassembling caliper - 6:45
Reinstalling caliper - 8:20
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We’re working with a 2011 Polaris Sportsman 850 ATV in this video, but the steps should be similar for the front brake caliper on all Polaris ATV models. If you’re not sure whether these steps apply to your ATV, leave a comment and we’ll get back to you.
RELATED CONTENT:
How to bleed the brakes on your Polaris ATV
• How to Bleed Polaris A...

[@austinburns8414]

thanks almost spent 280 on a new caliper

[@jasongreer9595]

Love the Partzilla videos. I have a 2001 Polaris Ranger 500. Does this model caliper have a cap/washer of some kind down in the hole on the caliper body where the brake line screws in? The piston was stuck in the caliper body and ended up using a larger punch and wallowed out the hole. Now I'm thinking that there was a small cap/washer that I was to remove. The parts diagrams don't show this part. How important is the hole size as long as the brake line will screw into the caliper body?

[@djnemesis82pluss1877]

Well you made that look easy my rzr burns threw brake pads in a day at the park I was going to just replace them but maybe I could just do what u did. Sounds a lot cheaper not sure if that's the problem yet though as I can compress the pistons back in pretty easily during pad change

[@PartzillaParts]

It's worth a try, Robes. Shoot us a comment if you get stuck and check out Partzilla if you need parts: www.partzilla.com/parts/search/Polaris/ATV/parts.html

[@djnemesis82pluss1877]

+Partzilla ok so I've done what u did here there was a pretty descent line of dirt build up on the pistons so I clean them with a wire wheel got them nice and smooth but I didn't replace the seals. I really figured since they weren't leaking they didn't need it but seems I'm still eating up pads in a day at the park and It seems that the master cylinder is good since there doesn't seem to be any pressure staying on the caliper after u pump the brakes and then loosen the bleed screw. So I figure only difference between my calipers and new ones are the seals.... I have replaced one caliper in the rear and fixed that corner so far it's the only one that keeps pads...thoughts ?

[@marie-elizeventer7080]

Thanks for the great tutorial!

[@erniepelley9554]

Your Videos give great information in a awesome format. I have replaced the caliper seals and my piston still doesn't go in the bore as easy as this one does. The bore and piston look good. I used plenty of DOT4 as lubricant. Im affraid once I put it back together like this my caliper with be sticking again. Do you have any suggestions? Thanks

[@zacmrochko436]

Great video. Rebuilding my '93 Polaris 350 2x4. Thank you!

[@639Beaver]

Great video.

[@PartzillaParts]

Thanks, Walter! Glad we could help!

[@austinburns8414]

my piston wouldn't retract took it apart and had lots of built up dirt on the piston

[@Tyler-gg5id]

Well I tried hitting the piston out, but every time I hit it, brake fluid shot out the bleeder valve.

[@sxscustom]

What is your part# for seals? This is the reason why I order my parts from #partzilla this guy is so knowledgeable. Great job guys

[@PartzillaParts]

Thanks for the compliment! What year model do you have? I can point you to the right diagrams.

[@petedumont2918]

Hi John, Great Video. My 94 4x4 has no front brakes. Where should I start? Calipers or brake handle? Fluid is ok.

[@PartzillaParts]

i would start at the calipers first and see if that is all you need to do.

[@bradseib4377]

I've followed your instructions for the rebuild but the brake is very tight when I reinstall it. It is not the piston that is making it tight. It is loose until I install the allen screw...then the pads get very tight to the disc. I haven't even attached the brake line yet.

[@PartzillaParts]

+Brad Seib You have the 5mm allen too far in the threads.Back it out about 3 to 4 turns.

[@AssassinActual23]

How do you replace the bleeder valve? I accidentally over tightened it & it came off.

[@PartzillaParts]

You over tightened it? Are the threads still in the caliper or did it sheer the threads?

[@AssassinActual23]

The treads are still in, the only thing that came off was the nut part if that makes any sense.

[@PartzillaParts]

You'll have to try to extract the remainder of the bleeder and then you should be able to screw in a new one.

[@mooxima]

that Allen screw should be tighten just enough so the outside pad barely touched the rotor, this was never mentioned in the video's

[@PartzillaParts]

You are very correct.

[@mdnghtwlf]

How tight do you put the Allen set screw in the back?

[@PartzillaParts]

It's just a cap, hand tight will be fine.

[@mdnghtwlf]

Partzilla Thanks.

[@sakircakr7886]

🇹🇷🇦🇿🇹🇷👍

[@Jr122T]

No no no. Do not use a punch. For the love of god. Dont advice diy novices to use a punch either. God forbid someone strikes it and it scores the side of the caliper. They're going to be out some money for a whole new caliper. Compressed air... a air compressor and a blower attachment with a rubber tip. Firmly Push it into the hole where the banjobolt was and let the air push the piston out. No chance of scoring or damaging something