Polaris RZR XP4 1000

9
9.35
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
Caliper Disassembly
1. Remove brake pad adjustment set screw
9
.
2. Push upper pad retainer pin inward and slip brake
pads
1
past the edge and remove from the caliper.
3. Remove mount bracket
2
and dust boots
6
&
7
.
4. Using a hammer and a small punch, remove the
piston
5
from the caliper body
8
. Remove the
square O-rings
4
and
3
from the caliper body
8
.
5. Clean the caliper body, piston, and retaining bracket
10
with brake cleaner or alcohol.
NOTE: Be sure to clean caliper body seal
grooves.
Caliper Inspection
1. Inspect caliper body for nicks, scratches or wear.
Measure bore size and compare to specifications.
Replace if damage is evident or if worn beyond
service limit.
Rear Caliper Piston Bore I.D.:
Standard: 1.505″ (38.23 mm)
Service Limit: 1.507″ (38.28 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
Rear Caliper Piston O.D.:
Standard: 1.500″ (38.10 mm)
Service Limit: 1.498″ (38.05 mm)
BRAKE SYSTEM