Caliper Inspection; Brake Pad Inspection; Rear Caliper Assembly - Polaris RZR XP Turbo Service Manual

BRAKE SYSTEM

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
Rear Caliper Piston Bore I.D.:
Standard: 1.505" (38.23 mm)
Service Limit: 1.507" (38.28 mm)
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn
beyond service limit.
MEASUREMENT
Rear Caliper Piston O.D.:
Standard: 1.500" (38.10 mm)
Service Limit: 1.498" (38.05 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
9.26

BRAKE PAD INSPECTION

Measure the thickness of the pad material and backing
plate with a caliper. Replace pads if worn beyond the
service limit.
MEASUREMENT
Brake Pad Thickness:
.296 ± .007"(7.53 ± .19 mm)
.180" (4.6 mm)

REAR CALIPER ASSEMBLY

1. Install new caliper seals
sure groove is clean and free of residue or brakes
may drag upon assembly.
2. Coat piston with clean Polaris DOT 4 Brake Fluid (PN
2872189). Install piston
while pushing inward. Piston should slide in and out
of bore smoothly with light resistance.
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in the caliper body . Be
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with a twisting motion
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