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GENERAL INFORMATION - BRAKE SYSTEM
SERVICE NOTES - BRAKE SYSTEM
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with finished
surfaces.
Disc brake systems are light weight, low maintenance,
and perform well in the conditions this vehicle will
routinely encounter. There are a few things to remember
when replacing disc brake pads or performing brake
system service to ensure proper system function and
maximum pad service life.
• DO NOT over-fill the master cylinder fluid reservoir.
• Make sure the brake pedal returns freely and
completely.
• Adjust the caliper stop pin after pad service.
• Check and adjust master cylinder reservoir fluid level
after pad service.
• Make sure atmospheric vent on reservoir is
unobstructed.
• Test for brake drag after any brake system service and
investigate cause if brake drag is evident.
• Make sure caliper moves freely on guide pins (where
applicable).
• Inspect caliper piston seals for foreign material that
could prevent caliper pistons from returning freely.
• Perform a brake burnishing procedure after installing
new pads to maximize service life.
• DO NOT lubricate or clean the brake components with
aerosol or petroleum products. Use only approved
brake cleaning products.
The Polaris brake system consists of the following
components or assemblies: brake pedal, master cylinder,
hydraulic brake lines, brake calipers, brake pads, and
brake discs, which are secured to the drive line.
When the foot activated brake lever is applied it applies
pressure on the piston within the master cylinder. As the
master cylinder piston moves inward it closes a small
opening (compensating port) within the cylinder and
starts to build pressure within the brake system. As the
pressure within the system is increased, the pistons
located in the brake calipers move outward and apply
pressure to the moveable brake pads. These pads
contact the brake discs and move the calipers in their
floating bracket, pulling the stationary side pads into the
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
brake discs. The resulting friction reduces brake disc and
vehicle speed.
The friction applied to the brake pads will cause the pads
to wear. As these pads wear, the piston within the caliper
moves further outward and becomes self adjusting. Fluid
from the reservoir fills the additional area created when
the caliper piston moves outward.
Brake fluid level is critical to proper system operation.
Too little fluid will allow air to enter the system and cause
the brakes to feel spongy. Too much fluid could cause
brakes to drag due to fluid expansion.
Located within the master cylinder is the compensating
port which is opened and closed by the master cylinder
piston assembly. As the temperature within the hydraulic
system changes, this port compensates for fluid
expansion or contraction. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for fluid expansion. Never
overfill the reservoir! Do not fill the reservoir beyond
the MAX LEVEL line!
When servicing Polaris brake systems use only Polaris
DOT 4 Brake Fluid (PN 2872189).
WARNING
Once a bottle of brake fluid is opened, use what is
necessary and discard the rest in accordance with
local laws. Do not store or use a partial bottle of
brake fluid. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture. This causes the boiling
temperature of the brake fluid to drop, which can
lead to early brake fade and the possibility of
serious injury.
SPECIAL TOOLS - BRAKE SYSTEM
TOOL DESCRIPTION
Mity Vac™ Pressure Test Tool
Bosch Automotive Service Solutions:
1-800-328-6657 or http://polaris.service-solutions.com/
BRAKE SYSTEM
9
PART NUMBER
2870975
9.3
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