9.44
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Std: 1.370 in (34.798 mm)
Service Limit: 1.368 in (34.760 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
BRAKE CALIPER ASSEMBLY - FRONT
1. Install new O-rings
w
in the caliper body. Be sure the
grooves
q
are clean and free of residue or brakes
may drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid
(PN 2872189). Install pistons 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
e
with silicone
grease and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seal boots 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. Refer to “Brake Pad Installation -
Front”page 9.40 procedure.
BRAKE CALIPER INSTALLATION - FRONT
1. Install the brake line onto the caliper taking care not
to allow any debris to enter the caliper.
2. Install the caliper and torque the mounting bolts to
specification.
TORQUE
Front Caliper Mount Bolts:
30 lb-ft (41 Nm)
NOTICE
If disc scraper was removed, reinstall it upon caliper
installation.
BRAKE SYSTEM
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