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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
3. Inspect the brake disc and pads as outlined in this
chapter.
Caliper Assembly
1. Install new O-rings (Item 2) in the caliper body. Be
sure the grooves (Item 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 (Item 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.
Caliper Installation
1. Install the brake line onto the caliper taking care not
to allow any debris to enter the caliper.
2. Install the caliper and torque the mounting bolts to
specification.
NOTE: If disc scraper (Item 1) was removed,
reinstall it upon caliper installation.
Front Caliper Mount Bolt (Item 2):
40 ft-lbs (54 Nm)
3. Torque the banjo bolt (Item 3) to specification.
Banjo Bolt
15 ft-lbs (20 Nm)
BRAKES
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