Polaris General XP 2021

10
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
10.1
BRAKE SYSTEM
CHAPTER 10
BRAKE SYSTEM
GENERAL INFORMATION - BRAKE SYSTEM .. . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .10.3
SERVICE NOTES - BRAKE SYSTEM . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. .10.3
SPECIAL TOOLS - BRAKE SYSTEM. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. .10.3
SERVICE SPECIFICATIONS - BRAKE SYSTEM (GENERAL / GENERAL 4) . ... . ... . .. . . ... . ... . ... . ..10.4
SERVICE SPECIFICATIONS - BRAKE SYSTEM (GENERAL XP / GENERAL XP 4) .. . . ... . ... . ... . .. . .10.5
SERVICE SPECIFICATIONS - BRAKE SYSTEM (INTL) . . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . .10.6
BRAKE SYSTEM SERVICE . . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..10.7
BRAKE SYSTEM OPERATION OVERVIEW.. . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . .10.7
BRAKE BLEEDING / FLUID CHANGE .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . .10.7
BRAKE BURNISHING PROCEDURE . . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . . .. . ... . ... . .. . . ... . ...10.8
ASSEMBLY VIEWS - BRAKE SYSTEM (GENERAL / GENERAL 4) . . ... . ... . . .. . . .. . ... . ... . ... . ... .10.9
BRAKE SYSTEM ASSEMBLY VIEW - GENERAL. .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ..10.9
BRAKE LINE ROUTING - GENERAL. . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. 10.11
BRAKE SYSTEM ASSEMBLY VIEW - GENERAL 4.. . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 10.14
BRAKE LINE ROUTING - GENERAL 4 . . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . 10.16
BRAKE CALIPER ASSEMBLY VIEW - GENERAL / GENERAL 4 . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . 10.19
BRAKE LINE FITTING ORIENTATION - GENERAL / GENERAL 4 . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . . 10.21
ASSEMBLY VIEWS - BRAKE SYSTEM (GENERAL XP / GENERAL XP 4) . . . .. . . .. . ... . ... . ... . .. 10.23
BRAKE SYSTEM ASSEMBLY VIEW - GENERAL XP . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... 10.23
BRAKE LINE ROUTING - GENERAL XP . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... 10.25
BRAKE CALIPER ASSEMBLY VIEW - GENERAL XP... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . 10.32
BRAKE SYSTEM ASSEMBLY VIEW - GENERAL XP 4 . . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . 10.34
BRAKE LINE ROUTING - GENERAL XP 4 . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . . 10.36
BRAKE CALIPER ASSEMBLY VIEW - GENERAL XP 4 ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. 10.43
BRAKE LINE FITTING ORIENTATION - GENERAL XP / GENERAL XP 4 . . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.45
MASTER CYLINDER SERVICE . .. . . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . .. 10.47
MASTER CYLINDER REMOVAL . . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. 10.47
MASTER CYLINDER INSTALLATION .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . 10.47
BRAKE PEDAL SERVICE. .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . . 10.48
BRAKE PEDAL REMOVAL . .. . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . 10.48
BRAKE PEDAL INSTALLATION. ... . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . ... . . .. . 10.48
FRONT PAD SERVICE. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . . 10.49
FRONT BRAKE PAD REMOVAL . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 10.49
BRAKE PAD INSPECTION . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . 10.50
BRAKE PAD INSPECTION (INTL). . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. 10.50
FRONT BRAKE PAD INSTALLATION . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. 10.50
FRONT CALIPER SERVICE - GENERAL / GENERAL XP / GENERAL 4 . .. . . .. . . .. . . .. . . .. . . .. . . . 10.52
FRONT CALIPER REMOVAL . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. 10.52
FRONT CALIPER DISASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... . . .. . . . 10.52
FRONT CALIPER INSPECTION . . . .. . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . .. 10.54
FRONT CALIPER ASSEMBLY . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. . . .. . . . 10.54