10.54
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.
FRONT CALIPER INSPECTION
1. Inspect caliper body for nicks, scratches, pitting or
wear. Measure bore size and compare to
specifications. Replace if damaged or worn beyond
service limit.
MEASUREMENT
Front Caliper Piston Bore I.D.:
Std: 1.373 in (34.874 mm)
Service Limit: 1.374 in (34.900 mm)
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Std: 1.370 in (34.798 mm)
Service Limit: 1.368 in (34.760 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
FRONT CALIPER ASSEMBLY
1. Install new O-rings
w
in the caliper body. Be sure the
grooves
q
are clean and free of residue or brakes
may drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid
(PN 2872189). Install pistons with a twisting motion
while pushing inward. Piston should slide in and out
of bore smoothly, with light resistance.
3. Lubricate the mounting bracket pins
e
with silicone
grease and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seal boots 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. Refer to “Brake Pad Installation - Front”
page 10.50 procedure.
BRAKE SYSTEM
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