Brake Burnishing Procedure - Polaris General 2020 Service Manual

BRAKE SYSTEM
3. Add brake fluid to the indicated MAX level of
reservoir.
Polaris DOT 4 Brake Fluid
(PN 2872189)
4. Begin bleeding procedure with the caliper that is
farthest from the master cylinder. Install a box end
wrench on caliper bleeder screw. Attach a clean,
clear hose to fitting and place the other end in a clean
container. Be sure the hose fits tightly on fitting.
5. Have an assistant slowly pump foot pedal until
pressure builds and holds.
6. Hold brake pedal down to maintain pedal pressure,
and open bleeder screw. Close bleeder screw and
release pedal.
IMPORTANT
Do not release foot pedal before bleeder screw is tight
or air may be drawn into master cylinder.
7. Repeat procedure until clean fluid appears in bleeder
hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.
IMPORTANT
Maintain at least 1/2"(1.27 cm) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
8. Tighten bleeder screw securely and remove bleeder
hose. Torque bleeder screw to specification.
TORQUE
Caliper Bleeder Screw:
4 lb-ft (5.4 Nm)
9. Repeat steps 5 - 8 for the remaining brake calipers in
the sequence shown at the beginning of the
procedure.
10.8
10. Add brake fluid to MAX level inside reservoir.
Master Cylinder Fluid Level
Up to MAX line inside reservoir
11. Install master cylinder reservoir cover.
12. Field test machine at low speed before putting into
service. Check for proper braking action and pedal
reserve. With pedal firmly applied, pedal reserve
should be no less than 1/2"(1.3 cm).
13. Check brake system for fluid leaks.

BRAKE BURNISHING PROCEDURE

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
9850067 R01 - 2020-2021 GENERAL / GENERAL XP Service Manual
© Copyright Polaris Inc.