BRAKES
9.13
FRONT CALIPER REASSEMBLY
1. Install new O-rings (A) in the caliper body (B). Be
sure groove is clean and free of residue or brakes
may drag upon assembly.
A
B
C
D
2. Coat piston with clean Polaris DOT 3 Brake Fluid
(C). 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, and install the
rubber dust seal boots.
Polaris Premium All Season Grease
(PN 2871423)
4. Compress the mounting bracket and make sure
the dust seals are fully seated. Install the pads as
shown on Page 9.10. Clean the disc and pads
with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
FRONT CALIPER
INSTALLA
TION
1. Install caliper on hub strut, and torque mounting
bolts.
18 ft. lbs. (25 Nm)
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm)
2. Install brake line and tighten securely with a line
wrench. Torque the brake lines to the proper
torque specification.
NOTE: See Page 9.3 to identify which style brake
line the ATV has installed.
Brake Line Torque
Banjo Style: 15 ft. lbs. (21 Nm)
Pipe Fit Style: 12--15 ft. lbs. (16--20 Nm)
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