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9929419 R02 - 2018-2019 RZR XP / XP 4 Turbo S Service Manual
© Copyright Polaris Industries 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.
BRAKE DISC INSPECTION
1. Visually inspect disc for scoring, scratches and
gouges. Replace disc if deep scratches are evident.
2. Using a micrometer, measure disc thickness at eight
different points around the pad contact surface.
MEASUREMENT
Brake Disc Thickness
.295 ± .008″(7.5 ± .2 mm)
Service Limit: .268″ (6.8 mm)
Brake Disc Thickness Variance:
Service Limit: 0.002″ (0.051 mm)
3. Mount a dial indicator. Slowly rotate the disc and read
runout on the dial indicator Replace disc if runout
exceeds specifications.
MEASUREMENT
Brake Disc Runout:
.010″ (0.25 mm)
BRAKE SYSTEM
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