Caliper Inspection; Caliper Assembly - Polaris Sportsman XP 1000 S 2020 Service Manual

4. Clean the caliper body, piston, and mounting bracket
with brake cleaner or denatured alcohol.
NOTICE
Be sure to thoroughly clean the seal grooves in the
caliper body.

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.
MEASUREMENT
Front Calipers:
Caliper Bore I.D.
Rear Caliper(s):
Caliper Bore I.D.
See "General Brake Specifications".
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
3. Inspect the brake pad and disc.
MEASUREMENT
Front Calipers:
Caliper Piston O.D.
Rear Caliper(s):
Caliper Piston O.D.
See "General Brake Specifications".

CALIPER ASSEMBLY

1. Install new O-rings in the caliper body.
NOTICE
Be sure seal grooves are clean or brakes may drag
upon assembly.
2. Coat piston with Polaris DOT 4 Brake Fluid. Install
piston with a twisting motion while pushing inward.
Piston should slide in and out of the bore smoothly,
with light resistance.
3. Lubricate the mounting bracket pins with silicone
grease and install the pin seal boot and pin bushing
boot.
BRAKE SYSTEM
10
10.35