Assembly - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

9. Measure the inside diameter of the rear caliper. The
caliper body is a 2-step piston. The rear step is
measured as well as the outside step.
Rear Caliper Piston Bore I.D.
Inner Bore Service Limit: .94" (23.88 mm)
Outer Bore Service Limit: 1.5" (38.1 mm)
10. Inspect caliper piston bore for scratches, severe
corrosion, or galling and replace if necessary.
11. Inspect surface of caliper piston for nicks, scratches,
or damage and replace if necessary.

Assembly

1. Install new O-rings in the slide bolt bushing holes. Be
2. Carefully assemble caliper body, making sure O-
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
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.
rings are properly positioned in groove. Tighten the
caliper anvil bolts and then torque the anvil bolts
evenly to specification.
Caliper Anvil Bolt:
16-18 ft-lbs (22-24 Nm)
BRAKES
9
9.25