Polaris TRAIL BOSS 2003 User Manual

BRAKES
9.19
10. Inspect surface of caliper piston for nicks,
scratches, or damage and replace if necessary.
REAR CALIPER ASSEMBLY
O-Rings
Piston Seals
1. Install new square-rings on piston. Be sure
square-ring grooves are thoroughly cleaned of all
residue, or piston may bind in bore. Apply brake
fluid to piston and install carefully with a twisting
motion to ease assembly. Install dust seal on
piston before fully seating piston.
2. Install new O-rings in caliper halves.
3. Carefully assemble caliper body, making sure
O-rings are properly positioned in groove. Apply
LocTitet242 (PN 2871949) to the allen head
screw and torque body screw evenly to 18 ft. lbs.
(25 Nm).
Caliper Halves Bolt Torque:
18 ft. lbs. (25 Nm)
4. Install brake pads in caliper body with friction
material facing each other. If equipped with a pad
spacer, install the spacer between the pads.
Install retaining pin through outer pad, pad spacer
and inner pad.
5. Install caliper and torque mounting bolts.
28 ft. lbs. (38 Nm)
Caliper Mounting Bolt Torque
28 ft. lbs. (38 Nm)

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English