Polaris RANGER XP 1000 2018-2019, Service Manual

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9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
© Copyright Polaris Industries Inc.
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
MEASUREMENT
Front Caliper Piston O.D.:
Standard: 1.370" (34.80 mm)
Service Limit: 1.368" (34.75 mm)
3. Inspect brake disc and pads as outlined in this
chapter.
CALIPER ASSEMBLY
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.
3. Lubricate the mounting bracket pins with silicone
grease and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
CALIPER INSTALLATION
1. Install caliper and torque mounting bolts to
specification.
NOTICE
If brake disc scraper was removed, be sure to reinstall it
upon caliper installation.
TORQUE
Front Caliper Mounting Bolts:
30 lb-ft (41 Nm)
BRAKE SYSTEM