Caliper Assembly; Caliper Installation - Polaris 2008 RZR Service Manual

BRAKES

Caliper Assembly

1. Install new caliper seals (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 4 Brake Fluid (PN
2872189). 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.
Polaris Premium All Season Grease
(PN 2871423)
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.
9.18
B
A

Caliper Installation

5. Install the rear caliper with the mounting bolts. Torque
mounting bolts to 18 ft. lbs. (24 Nm).
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
6. Install brake line banjo bolt and torque to specification.
7. Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
8. Perform brake bleeding procedure as outlined earlier in this
chapter.
9. Install wheel and torque wheel nuts to specification.
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)
NOTE: If new brake pads are installed, brake
burnishing is recommended (see "REAR BRAKE
PADS - Brake Burnishing Procedure").
18 ft. lbs.
(24 Nm)
= T
15 ft. lbs.
(21 Nm)
= T