10
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
10.31
REAR CALIPER ASSEMBLY
1. Install new caliper seals
q
in the caliper body
w
. Be
sure groove is clean and free of residue or brakes
may drag upon assembly.
2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN
2872189). Install piston
e
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
r
with silicone
grease and install the rubber dust seal boots
t
.
4. 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.
REAR BRAKE DISC INSPECTION
1. Visually inspect disc for scoring, scratches, or
gouges. Replace disc if deep scratches are evident.
2. Use a 0-1″ micrometer and measure disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
Brake Disc Thickness
.295 ± .008″(7.5 ± .2 mm)
.268″ (6.8 mm)
Brake Disc Thickness Variance:
Service Limit: 0.002″ (0.051 mm)
3. Mount a dial indicator and measure disc runout.
Slowly rotate the disc and read total runout on the dial
indicator. Replace the disc if runout exceeds
specifications.
Brake Disc Runout:
.010″ (0.25 mm)
BRAKE SYSTEM
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