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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
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.
WARNING
If brake pads are contaminated with grease,
oil, or liquid soaked do not use the pads.
Use only new clean pads.
3. Install caliper and torque bolts to specification.
Rear Caliper Mount Bolt:
18 ft-lbs (24 Nm)
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
inside reservoir and install reservoir cap.
Master Cylinder Fluid:
Up to MAX line inside reservoir
7. Install wheel and torque wheel nuts to specification.
Wheel Nuts:
Steel Wheels: 27 ft-lbs (37 Nm)
Aluminum Wheels: 30 ft-lbs + 90° (1/4 turn)
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.
Gradually 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).
BRAKES
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