Front Caliper Assembly; Brake Disc Inspection - Polaris RZR PRO XP 2020 Service Manual

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BRAKE SYSTEM

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.

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.

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.

Brake Disc Runout:

.010" (0.25 mm)

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

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