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POLARIS COMMERCIAL
CENTRE D'AIDE
08/25/2023

2023+ Pro XD Full-Size Gas Wheel and Brake System Inspection and Tire Rotation

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
  • Safety Glasses
  • Nitrile Gloves
  • Shop Rags

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris vehicle.

To inspect the wheels and brake system and perform a tire rotation on your Pro XD Full-Size Gas, 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, through the front grille. 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. Note: Do not allow brake fluid to contact painted surfaces or paint damage may occur.

3. Remove the tires from the vehicle.

  • Loosen the lug nuts before the vehicle is off the ground with a 19mm socket with 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 that 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. Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Also ensure the brake line retainers are properly secured.

9. Inspect the rear brake caliper and connection for leaks. 

10. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center

11. Take a look at the brake pads and rotors. Note: 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. Replace any brake pads that are worn beyond their minimum thickness, which is 0.040 inches (.762 millimeters).
  • Use a brake rotor measuring tool to measure the thickness of the brake rotors. Replace the rotors if they are worn below the minimum thickness, which is 0.170 inches (4.32 mm).

12. Once the brake system inspection has been completed, the tires can be rotated, if applicable, and reinstalled.

13. Rotate the wheels as needed based on wheel configuration. The Owner's Manual recommends every 500 miles (800 km). Note: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to the markings and directional indicators on the tires. 

  • Install the wheels on the vehicle and hand tighten the lug nuts.
  • 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 60 ft-lbs (81 Nm) in a crisscross pattern. 
  • Finally, lower the vehicle completely.

For more information, see your authorized Polaris Commercial Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.

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