Caliper Installation; Caliper Reassembly - Polaris 2009 Sportsman XP 850 Service Manual

Front Calipers:
Caliper Piston O.D.
Std: 1.186" (30.12 mm)
Service Limit: 1.184" (30.07 mm)
Rear Calipers:
Caliper Piston O.D.
Std: 1.250" (31.75 mm)
Service Limit: 1.246" (31.65 mm)

Caliper Reassembly

1. Install new O-rings (A) in the caliper body (B). Be sure
grooves are clean or brakes may drag upon assembly.
D
2. Coat piston with DOT 4 Brake Fluid (C). Install piston (D)
with a twisting motion while pushing inward. Piston should
slide in and out of the bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
= In. / mm.
C
B
A
4. Compress the mounting bracket and make sure the dust
seals are fully seated.
5. Install the brake pads.
6. Clean the disc and pads with brake parts cleaner or
denatured alcohol to remove any dirt, oil or grease.

Caliper Installation

1. Install caliper assembly over the brake disc and onto the
bearing carrier. Torque 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.
15 ft. lbs.
(20 Nm)
2. Install brake line and torque the banjo bolt fitting to
specification.
3. Perform brake bleeding procedure as outlined earlier in this
chapter.
4. Install the wheel and (4) wheel nuts. Torque wheel nuts to
specification.
Wheel Nuts:
Steel Wheels: 45 ft. lbs. (61 Nm)
Aluminum Wheels: 75 ft. lbs. (102 Nm)
BRAKES
Rear Caliper Shown
37 ft. lbs.
(50 Nm)
= T
11.13
11