Front Caliper Reassembly; Front Caliper Installation - Polaris SPORTSMAN 600 Service Manual

BRAKES

FRONT 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.
C
D
2. Coat piston with clean Polaris DOT 3 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, and install the
rubber dust seal boots.
Polaris Premium All Season Grease
(PN 2871423)
4. Compress the mounting bracket and make sure
the dust seals are fully seated. Install the pads as
shown on Page 9.10. Clean the disc and pads
with brake parts cleaner or denatured alcohol to
remove any dirt, oil or grease.
B
FRONT CALIPER
INSTALLATION
A
1. Install caliper on hub strut, and torque mounting
2. Install brake line and tighten securely with a line
NOTE: See Page 9.3 to identify which style brake
line the ATV has installed.
bolts.
Front Caliper Mounting Bolt Torque
18 ft. lbs. (25 Nm)
wrench. Torque the brake lines to the proper
torque specification.
Brake Line Torque
Banjo Style: 15 ft. lbs. (21 Nm)
Pipe Fit Style: 12- -15 ft. lbs. (16- -20 Nm)
18 ft. lbs. (25 Nm)
9.13