Brake Disc Service; Disc Inspection; Disc Removal / Replacement - Polaris Sportsman XP 1000 S 2020 Service Manual

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BRAKE SYSTEM

BRAKE DISC SERVICE

DISC INSPECTION

1. Visually inspect brake disc for scoring, scratches, or
gouges. Replace disc if deep gouges are evident.
2. Measure the disc thickness at 8 different points
around the pad contact surface using a 0–1"
micrometer. Replace disc if worn beyond service limit.
MEASUREMENT
Brake Disc Thickness
New: .187" / 4.75 mm
Service Limit: .167" / 4.24 mm
MEASUREMENT
Brake Disc Thickness Variance
Service Limit: .002" (.051 mm)
(difference between measurements)
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
specification.
MEASUREMENT
Brake Disc Runout
New: 0.02" / 0.51 mm (International Models)
Service Limit: .010" / .254 mm
10.38

DISC REMOVAL / REPLACEMENT

1. Loosen the (4) wheel nuts.
2. Elevate and support the side of the ATV in which the
brake disc is being serviced.
Use care when supporting vehicle so that it does not tip
or fall. Severe injury may occur if machine tips or falls.
3. Remove the wheel nuts and wheel.
4. Remove the axle nut cotter pin, the axle castle nut,
and cone washers.
5. Remove the (2) brake caliper mounting bolts.
IMPORTANT
Do not hang the caliper by the brake line. Use wire to
hang caliper to prevent damage to the brake line.
6. Remove the wheel hub assembly from the bearing
carrier and remove the brake disc.
7. Clean the wheel hub mating surface.
8. Install the new disc and press new wheel studs into
the hub until they are flush with the mating surface.
IMPORTANT
Always use new wheel studs if removed from the wheel
hub assembly.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
CAUTION
© Copyright Polaris Inc.

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