2009 Polaris Sportsman 850 XP EFI EPS Service Manual, Page 289Get this manual
BRAKES= In mmFront Calipers: Caliper Piston O.DStd: 1.186" (30.12 mm) Service Limit: 1.184" (30.07 mm) Rear Calipers: Caliper Piston O.DStd: 1.250" (31.75 mm) Service Limit: 1.246" (31.65 mm)
Compress the mounting bracket and make sure the dust seals are fully seatedInstall the brake padsClean the disc and pads with brake parts cleaner or denatured alcohol to remove any dirt, oil or grease
Caliper Installation
1Install caliper assembly over the brake disc and onto the bearing carrierTorque mounting bolts to specification
Caliper Reassembly
1Install new O-rings (A) in the caliper body (B)Be sure grooves are clean or brakes may drag upon assembly
New bolts have pre-applied locking agent which is destroyed upon removalAlways use new brake caliper mounting bolts upon assembly