10.58
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
FRONT CALIPER ASSEMBLY
1. Coat piston with clean Polaris DOT 4 Brake Fluid (PN
2872189). Install piston with a twisting motion while
pushing inward. Piston should slide in and out of bore
smoothly with light resistance.
2. Install new sealing o-rings inside the caliper.
3. Carefully press the pistons into the caliper.
4. Install the mount bracket assembly and dust boots.
5. Compress the mounting bracket and make sure the
dust seals 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.
FRONT 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.
TORQUE
Front Caliper Mount Bolts:
30 lb-ft (41 Nm)
NOTICE
If disc scraper was removed, reinstall it upon caliper
installation.
3. Torque the banjo bolt
q
to specification.
TORQUE
Brake Line Banjo Bolts:
15 lb-ft (20 Nm)
4. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
5. Bleed the brake system. Refer to “Brake Bleeding /
Fluid Change” page 10.7 procedure.
6. Install front wheels. Refer to “Wheel Installation”
page procedure.
7. Field test unit for proper braking action before putting
into service. Inspect for fluid leaks and firm brakes.
Make sure the brake is not dragging when pedal is
released. If the brake drags, re-check assembly and
installation.
NOTICE
If new pads are installed, refer to “Brake Burnishing
Procedure” page 10.8.
BRAKE SYSTEM
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