10.60
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
BRAKE PAD INSPECTION
Measure the thickness of the pad material. Replace pads
if worn beyond the service limit.
Brake Pad Thickness:
Std: 0.296 ± .007 in (7.53 ± .19 mm)
Service Limit: 0.180 in (4.6 mm)
REAR BRAKE PAD INSTALLATION
1. Lubricate mounting bracket pins
q
with a light film of
silicone grease and install rubber dust boots
w
.
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other.
WARNING
If brake pads are contaminated with grease, oil, or
liquid soaked do not use the pads. Use only new clean
pads.
3. Install the caliper and torque the new mounting bolts
to specification.
TORQUE
Rear Caliper Mounting Bolts:
46 lb-ft (62 Nm)
4. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2, (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
5. Install the adjustment set screw and turn clockwise
until the stationary pad contacts the disc, then back
off 1/2 turn.
6. Verify fluid level in reservoir is up to the MAX line
inside reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7. Install front wheels. Refer to “Wheel Installation”
page procedure.
NOTICE
If new pads are installed, refer to “Brake Burnishing
Procedure” page 10.8.
BRAKE SYSTEM
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