Rear Caliper Assembly - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION
5. Remove square-rings and dust seal.
square-ring grooves.
6. Clean disc, caliper body, and piston with brake
cleaner or alcohol.
Rear Caliper
Inspect Bores
7. Inspect caliper piston bores for wear, scratches,
severe corrosion, or galling.
necessary.
Rear Caliper Piston Bore I.D.
Std. 1.68" (42.67mm)
Replace if bore is worn or damaged
8. Inspect surface of caliper piston for nicks,
scratches, or damage and replace if necessary.

REAR CALIPER ASSEMBLY

Dust Seal
O-Rings
1. Install new square-rings on piston.
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.
Clean 2. Seat dust seal in caliper body.
3. Install new O-rings in caliper mounting ears.
4. Install caliper and brake pads with friction material
facing each other on brake disc.
5. Apply LocTitet242 (PN 2871949) and torque
mounting bolts to 15 ft. lbs. (21 Nm).
Left Brake Line
Replace if
Right Brake Line
6. Install brake lines and securely tighten.
7. Follow bleeding procedure outlined on Pages
9.7--9.8 of this section and refer to system
overview and illustration on Page 9.5.
8. Field test unit for proper braking action before
putting into service. Inspect for fluid leaks and
firm brakes. Make sure the brake is not dragging
when lever is released.
re-check assembly and installation.
Be sure
Caliper Mounting Bolt Torque:
15 ft. lbs. (21 Nm)
If the brake drags,
9.19