6.15
BRAKES
Reassembly
1. Install new piston square 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 3 or DOT 4 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. Install new slide pin O-rings in the caliper body for the
Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install..
NOTE: Do not use Polaris Premium All Season
Grease (PN 2871423) on the square seals. The
petroleum based lubricant will cause the square
seals to swell up.
4. Compress the mounting bracket into the caliper and make
sure the O-rings 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.
Installation
1. Install caliper on hub strut, and torque mounting bolts.
2. Install brake line and tighten securely with a line wrench.
Torque the banjo brake lines to the proper torque
specification.
3. Perform brake bleeding procedure as outlined earlier in
this chapter.
4. Install wheels and torque wheel nuts to specification (See
Chapter 2).
A
B
C
NOTE: O-ring grooves are size-specific
15 ft.lbs. (20 Nm)
22 ft.lbs.
(30 Nm)
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