9
9.25
9925724 R01 - 2014-2015
RZR
XP 1000 /
RZR
XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
Caliper Inspection
1.
Inspect caliper body for nicks, scratches, pitting or
wear.
Measure
bore
size
and
compare
to
specifications. Replace if damaged or worn beyond
service limit.
Front Caliper Piston Bore I.D.:
Std: 1.373” (34.87 mm)
Service Limit: 1.375” (34.93 mm)
2.
Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
Front Caliper Piston O.D.:
Std: 1.370” (34.80 mm)
Service Limit: 1.368” (34.75 mm)
3.
Inspect the brake disc and pads as outlined in this
chapter.
Caliper Assembly
1.
Install new O-rings
2
in the caliper body. Be sure the
grooves
1
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
3
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.
BRAKE SYSTEM
Summary of Contents for RZR XP 1000
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