Caliper Removal; Brake Burnishing Procedure; Caliper Disassembly; Caliper Service - Polaris 2009 Sportsman XP 850 Service Manual

3. Install the caliper and torque new mounting bolts to
specification.
CAUTION
New bolts have a pre-applied locking agent
which is destroyed upon removal. Always use
new brake caliper mounting bolts
upon assembly.
4. Slowly pump the brake lever/pedal until pressure has been
built up. Maintain at least 1/2, (12.7 mm) of brake fluid in
the reservoir to prevent air from entering the brake system.
5. Verify fluid level in reservoir is at specified level inside
reservoir and install reservoir cap.
6. Install the wheel(s) and wheel nuts. Torque wheel nuts to
specification.
Wheel Nuts:
Steel Wheels: 45 ft. lbs. (61 Nm)
Aluminum Wheels: 75 ft. lbs. (102 Nm)

Brake Burnishing Procedure

It is required that a burnishing procedure be performed after
installation of new brake pads to extend service life and reduce
noise.
Start machine and slowly increase speed to 30 mph. Gradually
apply brakes to stop machine. Allow pads and disc to cool
sufficiently during the procedure. Do not allow pads or disc to
become hot or warping may result. Repeat this procedure 10
times.
Rear Caliper Shown
37 ft. lbs.
(50 Nm)
= T

CALIPER SERVICE

Caliper Removal

1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the caliper
is being serviced.
CAUTION
Use care when supporting vehicle so that it does
not tip or fall. Severe injury may occur if
machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Place a suitable container under the caliper to catch brake
fluid draining from brake line. Using a wrench, loosen and
remove brake line from the caliper.
5. Remove (2) caliper mounting bolts and remove the caliper
assembly from the bearing carrier.

Caliper Disassembly

1. Push mounting bracket inward and slip the outer brake pad
past the edge of the pin. Remove the inner brake pad.
BRAKES
Rear Caliper Shown
Remove
11
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