9.16
BRAKES
5. Push caliper piston into the 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 excess fluid from reservoir as required.
6. Push caliper mounting bracket inward and slip outer brake
pad past the edge to remove.
7. Remove the inner brake pad.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Pad Assembly / Installation
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots.
2. Compress mounting bracket and make sure dust boots are
fully seated. Install pads with friction material facing each
other.
Rear Brake Pad Thickness
New .298” ± .007” (7.57 mm ± .178 mm)
Service Limit .180” (4.6 mm)
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
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