9.16
BRAKES
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 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.
3. Install caliper onto front hub and torque mounting
bolts to specification.
4. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2" (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
5. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside
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.
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).
If brake pads are contaminated with grease, oil,
or liquid soaked do not use the pads.
Use only new, clean pads.
Front Caliper Mount Bolt:
40 ft-lbs (54 Nm)
Apply Grease to Each
Bracket Pin
Master Cylinder Fluid
Up to MAX line inside reservoir
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)
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