Brake Disc Inspection; Front Brake Disc Replacement; Brake Caliper / Pad Installation - Polaris RZR XP Turbo Service Manual

BRAKE SYSTEM

BRAKE DISC INSPECTION

1. Visually inspect disc for scoring, scratches and
gouges. Replace disc if deep scratches are evident.
2. Using a micrometer, measure disc thickness at eight
different points around the pad contact surface.
MEASUREMENT
Brake Disc Thickness
.295 ± .008"(7.5 ± .2 mm)
Service Limit: .268" (6.8 mm)
Brake Disc Thickness Variance:
Service Limit: 0.002" (0.051 mm)
3. Mount a dial indicator. Slowly rotate the disc and read
runout on the dial indicator Replace disc if runout
exceeds specifications.
MEASUREMENT
Brake Disc Runout:
.010" (0.25 mm)

FRONT BRAKE DISC REPLACEMENT

1. Remove the hub cotter pin, castle nut and washers.
2. Remove the wheel hub assembly from the vehicle by
pulling straight out.
3. Press out the four studs retaining the disc to the hub.
4. Replace the brake disc with a new one.
5. Press in new wheel studs to retain the disc to the hub.
6. Install hub onto the vehicle. Install the two washers
and new castle nut. Torque fastener to specification.
TORQUE
Wheel Hub Castle Nut:
180 ft-lbs (244 Nm)
7. Install new cotter pin into castle nut and install wheel
cap.
9.22

BRAKE CALIPER / PAD INSTALLATION

q
1. Install the bolt retaining the brake line fitting to the
caliper. Properly orient the brake line fitting to the
caliper as shown. Torque banjo bolt to specification.
The vertical centerline used for measurement is based
on the caliper pin locations.
TORQUE
Brake Line Banjo Bolt:
15 ft-lbs (20 Nm)
2. Install the inner pad on the bracket and caliper.
3. Install the outer brake pad between the bracket and
caliper body.
4. Install the caliper on the knuckle. Torque mounting
fasteners to specification.
TORQUE
Brake Caliper Mounting Bolts:
30 ft-lbs (42 Nm)
5. 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.
6. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
7. Install the front wheel and the wheel nuts.
TORQUE
Wheel Lug Nuts:
120 ft-lbs (163 Nm)
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
NOTE
© Copyright Polaris Industries Inc.