Required Tools and Supplies
- 19mm Socket
- Torque Wrench
- Breaker Bar
- Brake Pad Measurement Tool
- Tire Pressure Gauge
- Tread Depth Gauge
- Flashlight
- Brake Fluid
- Eye Protection
- 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 Diesel, follow these steps.
1. Take a close look at each tire.
- Inspect for damage that may compromise the integrity of the tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
- 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.
- Lastly, take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. View the brake fluid level at the reservoir in the driver’s side wheel well. The level should be between the upper (MAX) and lower (MIN) level lines. Ensure the level is between the min and max marks.
3. If the fluid level is lower than the upper-level line, access the brake fluid reservoir through the driver’s side wheel well and add brake fluid as needed. Note: Do not allow brake fluid to contact painted surfaces or paint damage may occur.
4. To inspect the parking brake, start by applying the service brakes and then pull the parking brake lever.
5. Verify the following:
- The ratchet teeth should be heard and felt as the locking pawl clicks into place
- After a few clicks, the parking brake indicator lamp on the instrument cluster should illuminate
- The rear wheels of the vehicle should not rotate when turning by hand
- Ensure that plenty of resistance is felt in the lever’s throw before fully extending to a hard stop.
6. When the parking brake is fully engaged, the vehicle should not roll while parked.
7. If the parking brake fails inspection, contact your Polaris Dealer for adjustments or repairs.
8. Remove the tires from the vehicle.
- Loosen the lug nuts before the vehicle is off the ground with a 19mm socket with a breaker bar, but do not remove them 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.
9. 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.
10. 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.
11. Inspect the connections at the front brake calipers for leaks.
12. Follow the brake lines back to the rear of the vehicle, checking for leaks, kinks and damage.
13. Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Ensure that the brake line retainers are properly secured.
14. Inspect the rear brake caliper and connection for leaks.
15. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
16. Take a look at the brake pads. 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 of 0.040 inches (1mm).
- New front brake pads are part number 2205949. New rear brake pads are part number 2203318.
17. Once the brake system inspection has been completed, the tires can be rotated, if applicable, and reinstalled.
18. Rotate the wheels as needed based on wheel configuration. 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 specification in a crisscross pattern. Torque steel wheels to 60 ft-lbs (81 Nm), and torque aluminum.
- 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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