10
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
10.5
SERVICE SPECIFICATIONS - BRAKE SYSTEM (GENERAL XP / GENERAL XP 4)
FRONT BRAKE SYSTEM
ITEM
STANDARD SERVICE LIMIT
Front Brake Pad Thickness
0.296 ± .007 in (7.53 ± .19 mm) 0.180 in (4.6 mm)
Front Brake Disc Thickness
0.295±.008 in (7.5±.2 mm) 0.268 in (6.8 mm)
Front Brake Disc Thickness Variance
-
0.002” (0.051 mm)
Front Brake Disc Runout
-
0.010" (0.254 mm)
Dual Piston Caliper (General XP)
Front Caliper Piston Bore I.D. 1.373 in (34.874 mm) 1.374 in (34.900 mm)
Front Caliper Piston O.D. 1.370 in (34.798 mm) 1.368 in (34.760 mm)
Triple Piston Caliper (General XP 4)
Front Caliper Piston Bore I.D.
Large Bore: 1.375″ (34.93 mm)
Medium Bore: 1.188″ (30.18 mm)
Small Bore: 1.000″ (25.4 mm)
Front Caliper Piston O.D.
Large: 1.3685-1.3700″ (34.76-34.80
mm)
Medium: 1.1860-1.1875″ (30.12-
30.16 mm)
Small: .9985-1.000″ (25.36-25.40
mm)
REAR BRAKE SYSTEM
ITEM
STANDARD SERVICE LIMIT
Rear Brake Pad Thickness
0.296 ± .007 in (7.53 ± .19 mm) 0.180 in (4.6 mm)
Rear Brake Disc Thickness
0.188 in (4.775 mm) 0.181 in (4.597 mm)
Rear Brake Disc Thickness Variance
-
0.002” (0.051 mm)
Rear Brake Disc Runout
-
0.010" (0.254 mm)
Single Piston Caliper (General XP)
Rear Caliper Piston Bore I.D. 1.505" (38.23 mm) 1.507" (38.28 mm)
Rear Caliper Piston O.D. 1.500" (38.10 mm) 1.498" (38.05 mm)
Dual Piston Caliper (General XP 4)
Rear Caliper Piston Bore I.D. 1.191 in (30.251 mm) 1.192 in (30.277 mm)
Rear Caliper Piston O.D. 1.187 in (30.162 mm) 1.186 in (30.124 mm)
GENERAL SPECIFICATIONS
Brake Fluid Type
Polaris DOT 4
Brake Fluid PN 2872189
Brake Fluid Capacity
Up to MAX line inside reservoir
Brake Pedal Free-Play
0.090 in (2.28 mm)
BRAKE SYSTEM
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