9.20
BRAKES
Caliper Assembly
1. Install new caliper seals (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes may drag
upon assembly.
2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN
2872189). Install piston (D) with a twisting motion while
pushing inward. Piston should slide in and out of bore
smoothly with light resistance.
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
4. Compress the mounting bracket and make sure the dust
seals are fully seated. Install the brake pads. Clean the disc
and pads with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
Caliper Installation
1. Install the rear caliper with the mounting bolts. Torque
mounting bolts to specification.
2. Install brake line banjo bolt and torque to specification.
3. Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
4. Follow bleeding procedure outlined earlier in this chapter.
5. Install wheel and torque wheel nuts to specification.
NOTE: If new pads are installed, refer to “REAR
BRAKE PADS - Brake Burnishing Procedure”.
Polaris Premium All Season Grease
(PN 2871423)
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
Wheel Nuts:
Steel Wheels: 35 ft. lbs. (47 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
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