9.19
BRAKES
9
9924125 - 2013 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2012 Polaris Sales Inc.
Pad Inspection
1. Clean the caliper with brake cleaner or alcohol.
2. Measure the thickness of the pad material. Replace
p
ads if worn beyond the service limit.
Pad Assembly / Installation
1. Lubricate mounting bracket pins with a light film of
silicone grease and install rubber dust boots.
2. Compress mounting bracket
and make sure dust
boots are fully seated. Install pads with friction
material facing each other.
3. Install caliper and torque bolts to
specification.
4. Slowly pump brake pedal until pressure has been built
up. Maintain at least 1/2, (12.7 mm) of brake fluid in
reservoir to prevent air from entering brake system.
5. Install adjustment set screw and
turn clockwise until
stationary pad contacts disc, then back off 1/2 turn.
6. Verify fluid level in reservoir is up to the MAX line
i
nside reservoir and install reservoir cap.
7. Install wheel and torque wheel nuts to
specification.
Brake Burnishing Procedure
It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gra
dually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
Rear Brake Pad Thickness
New .298” ± .007” (7.57 mm ± .178 mm)
Service Limit .180” (4.6 mm)
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
Rear Caliper Mount Bolt:
18 ft-lbs (24 Nm)
Master Cylinder Fluid:
Up to MAX line inside reservoir
Wheel Nuts:
Steel Wheels: 27 ft-lbs (37 Nm)
Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn)
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