New Brake Pad Installation; Caliper Installation; Parking Brake Disc Service; Disc Removal / Inspection - Polaris RANGER XP 700 4X4 Service Manual

BRAKES

New Brake Pad Installation

NOTE: Parking Brake Pads can be replaced by
ordering one of the following kits:
PN 2203148 - Brake Pad and Shim Kit
PN 2203147 - Brake Pad Kit
There may be more parts in the service kit than your
brake requires. Check the parts list included with
the kit for the exact quantities.
1. Using the stationary actuator, assemble the caliper
components as shown below. Do not install the springs or
shims yet. Measure the gap for the brake disc.
Disassemble and add shims between thrust washer and the
inside brake pad as needed to close the gap to 0.203"-
0.193" (5.156-4.902 mm). For shim location, see Figure
9.10 on page 10.
Add shims until gap
measures 0.203"- 0.193"
(5.156 - 4.902 mm)
2. Once you have determined the correct amount of shims to
use, install the assembly bolts through the sleeves. Install
the nuts and the correct amount of shims, the inner brake
pad, springs, and outer brake pad. Torque the assembly
nuts to 25 ft. lbs. (34 Nm).
Parking Brake Caliper - Assembly Bolts:
25 ft. lbs. (34 Nm)
3. Ensure the park brake assembly functions properly by
actuating the lever before reinstallation.
9.12
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Caliper Installation

1. Install the park brake assembly into place. Tighten the two
mounting bolts in increments for proper installation.
18 ft. lbs.
(24 Nm)
4x4 Model Shown
2. Torque the two mounting bolts to 18 ft. lbs. (24 Nm).
Parking Brake Caliper - Mounting Bolts:
18 ft. lbs. (24 Nm)
3. Install the cable, pin, and clip pin. Test the park brake for
proper function.

PARKING BRAKE DISC SERVICE

Disc Removal / Inspection

1. Measure the park brake disc with a micrometer. The
minimum allowable thickness of the disc should be .161"
(4.09 mm). If the thickness of the disc is less than
specified, replace the rear propshaft / disc assembly.
2. Follow the "Rear Prop Shaft Removal (4x4 & 6x6)"
procedure in Chapter 7 to remove the rear prop shaft / disc
assembly.
4x4 Shaft Shown
Remove Bolts
Minimum Disc Thickness: 0.140" (3.56 mm)
New Disc: 0.150" - 0.164" (3.81 - 4.16 mm)
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