Assembly - Polaris 2007 SPORTSMAN X2 800 Service Manual

BRAKES
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.
.94in. (23.88) mm)
1.5 in. (38.1 mm)
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.
9.24
= In. / mm.
Inspect

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
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 specification.
16-18
Caliper Anvil Bolt Torque:
16-18 ft.lbs. (22-24 Nm
3. Install brake pads in caliper body with friction material
facing each other. Install the slide pins and the slide pin
retaining rings. Torque the slide pins to specification.
ft.lbs. (22-24
= T
)