Rear Caliper Assembly - Polaris SPORTSMAN 600 2003 Service Manual

REAR CALIPER ASSEMBLY

1. Install new O-rings in the slide bolt bushing holes.
Be sure O-ring and seal grooves are thoroughly
cleaned of all residue, or piston may bind in bore.
Apply brake fluid to piston seals and install
carefully with a twisting motion to ease assembly
until fully seated.
Seals
O-Rings
2. Carefully assemble caliper body, making sure
O-rings are properly positioned in groove.
Tighten the caliper anvil bolts and then torque the
anvil bolts evenly to 16--18 ft. lbs. (22--25 Nm).
Caliper Anvil Bolt Torque:
16- -18 ft. lbs. (22 Nm- -25 Nm)
3. Install brake pads in caliper body with friction
material facing each other. Install the slide pins
and the slide pin retaining ring. Torque the slide
pins to 30--35 ft.lbs. (41--48 Nm).
9.18
Caliper Slide Pin Torque:
30- -35 ft. lbs. (41 Nm- -48 Nm)
4. Install caliper and torque mounting bolts to 18
ft.lbs (25 Nm).
Torque Mounting
Bolts
Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm)
BRAKES BRAKES