6.12
BRAKES
Front Brake Pad Assembly / Caliper
Installation
1. Lubricate mounting bracket pins with a light film of
Polaris Premium All Season Grease (PN 2871423), and
install rubber dust boots. Be sure dust boots are fully
seated on caliper bracket and on caliper body.
2. Push mounting bracket as far as possible toward the piston
side of the caliper. Install pads with friction material facing
each other.
3. Screw guide pin (A) through both pads and on to threaded
bracket post. Install pin until it stops against bracket (B).
Pads must slide freely on the pin. The guide pin will be fully
tightened after caliper is installed. Be sure boots (C) are
seated on caliper and on bracket.
4. Install caliper onto front hub. Torque both mounting bolts.
5. Torque brake pad guide pin(s) that were loosened or
removed.
6. Slowly pump brake pedal until pressure builds. Maintain at
least 1/2 inch (12.7 mm) of brake fluid in reservoir to
prevent air from entering the brake system.
7. Rotate wheel hub and verify the hub turns freely without
brake drag.
8. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
9. Install wheel and torque wheel nuts.
10. Perform the Brake Burnishing Procedure to maximize pad
service life and minimize noise. See “Brake Burnishing
Procedure” on page 6.18.
If brake pads are contaminated with grease, oil,
or liquid soaked do not use the pads.
Use only new, clean pads.
Caliper Mount Bolt Torque:
18 ft. lbs. (24.5 Nm)
Front Wheel Nut Torque:
27 ft. lbs. (37 Nm)
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