Polaris RZR PRO XP 2020, Service Manual

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10.22
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
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.
FRONT CALIPER DISASSEMBLY /
INSPECTION (4-SEAT)
1. Remove the mount bracket assembly
q
and dust
boots
w
.
2. Thoroughly clean the caliper before disassembly and
prepare a clean work area for disassembly.
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.
BRAKE SYSTEM