Polaris Outlaw 500, Service Manual, Page: 170 / 202

6.21
BRAKES
6
4. With pads installed, push caliper piston into caliper bore
(A) slowly using a C–clamp (B) or locking pliers.
NOTE: Brake fluid will be forced through
compensating port into master cylinder fluid
reservoir when piston is pushed back into caliper.
Remove excess fluid from reservoir as required.
5. Remove the c-clips (C) on the ends of the caliper slide bolt.
6. Remove caliper slide bolts (D) and brake pads (E).
7. Measure the thickness of the pad material. Replace pads if
worn beyond the service limit.
Pad Installation
1. Install new pads (A) in caliper body. Slide the caliper slide
bolts (B) into the caliper and hand-tighten.
2. Install the caliper assembly over the brake disc and onto the
caliper mount.
Tip the caliper forward and install only the
forward bolt. This will allow both slide bolts to be torqued
to specification.
TIP: Use a block or wedge to keep the
caliper stationary while tightening the slide bolts.
A
B
C
D
E
Brake Pad Thickness
New: .298” / 7.6 mm
Service Limit: .180” / 4.6 mm
Brake Caliper Mounting Bolt
Torque:
18 ft. lbs. (24 Nm)
A
B