Caliper Assembly - Polaris 2011 RANGER RZR Service Manual

Caliper Assembly

1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may drag
upon assembly.
New
O-Rings
2. Coat pistons with clean Polaris DOT 4 Brake Fluid. Install
pistons 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 silicone grease
and install the rubber dust seal boots.
Apply Grease to Each
Bracket Pin
4. Compress the mounting bracket and make sure the dust seal
boots 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 the brake line onto the caliper taking care not to
allow any debris to enter the caliper.
2. Install the caliper and torque the mounting bolts to
specification.
Seal
Grooves
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
IMPORTANT: If disc scraper was removed, reinstall it
upon caliper installation (RZR 4 Only).
Disc
Scraper
RZR 4
Shown
Front Caliper Mount Bolt Torque:
31-34 ft. lbs. (42-46 Nm)
3. Torque the banjo bolt to the proper torque specification.
RZR / RZR S
RZR 4
BRAKES
31-34 ft. lbs.
(42-46 Nm)
= T
15 ft. lbs.
(20 Nm)
15 ft. lbs.
(20 Nm)
9.15
9