Polaris PREDATOR 2003, Service Manual

Page: 162 / 193

BRAKES
6.17
2. Inspect piston for nicks, scratches, wear or
damage. Replace if damaged or worn.
Inspect Piston
3. Inspect the brake disc and pads as outlined for
brake pad replacement this section. See Page
9.9--9.11.
FRONT / REAR CALIPER
ASSEMBLY
1. Reassemble the two caliper halves if previously
disassembled. Torque the caliper body bolts to 18
ft.lbs. (25 Nm) .
18 ft. lbs.
(25 Nm)
2. Install new O-ring (A) in the caliper body. Install
the dust boot over the caliper and seat the dust
boot into caliper groove. Be sure groove is clean
and free of residue or brakes may drag.
A B
3. Coat piston and inside of caliper body with clean
DOT 3 Brake Fluid ( PN 2870990 ). Install piston
with a twisting motion while pushing inward.
Piston should slide in and out of bore smoothly,
with light resistance.
NOTE: Be sure that the O--ring does not bind
when installing the piston.
4. Seat the dust boot securely onto the caliper body.
5. Install the caliper mount (C), brake pads (D),
caliper slide bolts (E), and c--clips (F).
C
D
E
F
6. Torque the caliper slide bolts (E) to 33 ft.lbs. (45
Nm) .
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