Caliper Reassembly; Caliper Installation - Polaris Outlaw 500 Service Manual

BRAKES

Caliper Reassembly

1. Install new O-rings (A) in the caliper body (B). Be sure
groove is clean and free of residue or brakes may drag
upon assembly.
D
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. Lubricate the mounting bracket pins with Polaris Premium
All Season Grease (PN 2871423), and install the rubber
dust seal boots.
6.14
C
B
A
4. Compress the mounting bracket and make sure the dust
seals 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.

Caliper Installation

1. Install caliper and torque mounting bolts.
18 ft. lbs
(24 Nm)
2. Install brake line and tighten securely with a line wrench.
Torque the banjo brake lines to the proper torque
specification.
3. Install the adjuster screw and turn until stationary pad
contacts disc, then back off 1/2 turn.
4. Perform brake bleeding procedure as outlined earlier in this
chapter.
5. Install wheels and torque wheel nuts to specification.
15 ft.lbs. (20 Nm)
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