9.22
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
Disc Inspection
1. Visually inspect disc for scoring, scratches or
gouges. Replace the disc if any deep scratches are
evident.
2. Use a 0-1” micrometer and measure disc thickness
at eight different points around the pad contact
surface. Replace disc if worn beyond service limit.
Brake Disc Thickness:
Standard: 0.188” (4.78 mm)
Service Limit: 0.170” (4.32 mm)
Brake Disc Thickness Variance:
Service Limit: 0.002” (0.051 mm)
difference between measurements
Disc Replacement
1. Remove the front brake caliper (see “FRONT
CALIPER SERVICE”).
2. Remove wheel hub cotter pin, castle nut and
washers.
3. Remove the wheel hub assembly from the vehicle
and remove the (4) bolts retaining the disc to the
hub.
4. Clean the wheel hub mating surface and install new
disc on wheel hub.
5. Install new bolts and torque to 18 ft-lbs (24 Nm).
CAUTION
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
BRAKES
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