9850067 R01 - 2020-2021
GENERAL
/
GENERAL XP
Service Manual
© Copyright Polaris Inc.
10.57
3. Use a commercially available caliper piston pliers to
extract the pistons
e
from the caliper
IMPORTANT
Do not remove the caliper pistons with a standard
pliers. The piston sealing surface will become damaged
if a standard pliers is used.
4. Once the pistons are removed, use a pick to carefully
remove the o-rings
r
from the caliper. O-rings should
be replaced during caliper service.
5. Clean the caliper body, pistons, and retaining bracket
with brake cleaner or alcohol.
NOTICE
Be sure to clean all the seal grooves in the caliper body.
6. Inspect caliper body for nicks, scratches, pitting or
wear.
7. Measure bore size and compare to specifications.
Replace if damaged or worn beyond service limit.
MEASUREMENT
Front Caliper Piston Bore I.D.:
Large Bore: 1.375″ (34.93 mm)
Medium Bore: 1.188″ (30.18 mm)
Small Bore: 1.000″ (25.4 mm)
8. Inspect piston for nicks, scratches, pitting or wear.
9. Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Large: 1.3685-1.3700″ (34.76-34.80 mm)
Medium: 1.1860-1.1875″ (30.12-30.16 mm)
Small: .9985-1.000″ (25.36-25.40 mm)
10. Inspect the brake disc and pads as outlined in this
chapter.
