Required Tools and Supplies
- 19mm Socket
- Torque Wrench
- Breaker Bar
- Brake Rotor Measurement Tool
- Brake Pad Measurement Tool
- Tire Pressure Gauge
- Tread Depth Gauge
- Flashlight
- Brake Fluid
- Mirror
- Safety Glasses
- Nitrile Gloves
- Shop Towels
For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris XPEDITION.
To inspect the wheels and brake system and perform a tire rotation on your Polaris XPEDITION XP or ADV, follow these steps:
1. Take a close look at each tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach 1/8 inch or 3 millimeters of tread depth.
- Inspect for damage that may compromise the integrity of the tire.
- Inspect the tire pressure and verify it is set to specification. Reference the Owner’s Manual or tire pressure label on your vehicle for the correct specification.
- Take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. Inspect the fluid level and condition in the master cylinder, located in the driver’s side front wheel well. Ensure the level is between the min and max marks. If it is low, clean around the cap and add fluid as necessary from a new and unopened bottle. Ensure the diaphragm is collapsed before reinstalling to prevent overspill. Warning: Do not allow brake fluid to contact painted surfaces or paint damage may occur.
3. Remove the wheels from the vehicle.
- Loosen the lug nuts while the vehicle is on the ground with a 19mm socket with a breaker bar, but do not them remove at this time.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Once safely elevated, remove the lug nuts and set aside.
- Remove the wheels and set aside.
4. Inspect the banjo bolts on the passenger side of the master cylinder for leaks. Tip: A mirror and flashlight can be used to help see the bolts.
5. Follow the lines all the way to the front calipers, looking for any leaks, kinks or damage. Also ensure the brake line retainers are properly secured.
6. Inspect the connections at the front brake calipers for leaks.
7. Follow the brake lines back to the rear of the vehicle, checking for leaks, kinks and damage.
8. Inspect the connections at the junction block in the passenger’s rear wheel well for leaks.
9. Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Also ensure the brake line retainers are properly secured.
10. Inspect the rear brake calipers and connections for leaks.
11. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
12. Take a look at the brake pads and rotors. Warning: Always allow the brakes to cool completely before inspecting to prevent the risk of burns.
- Check the brake pad thickness using a suitable tool. Be sure to check the thickness on the inside pads as well and replace any brake pads that are worn beyond their minimum thickness, which is 0.030 inches (0.762 mm).
- Use a brake rotor measuring tool to measure the thickness of the brake rotors and replace the rotors if they are worn below the minimum thickness, which is 0.268 inches (6.8mm).
13. Once the brake system inspection has been completed, the tires can be rotated and reinstalled. Note: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to all markings and directional indicators on the tires.
14. Rotate the wheels as needed based on wheel configuration.
- Install the wheels on the vehicle, and tighten the lug nuts until fully seated.
- Once installed, safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torquing.
- Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
- Finally, lower the vehicle completely.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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