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POLARIS OFF-ROAD VEHICLES
CENTRO DE AYUDA
9/8/2023

2021+ RZR 200 EFI Front Brake Pad Removal and Installation

Required Tools and Supplies

  • 4mm Long Allen Socket
  • 10mm Socket
  • 15mm Socket
  • Torque Wrench
  • C-Clamp or Locking Pliers
  • Wire Hanger, Rope or Retention Strap
  • Safety Glasses
  • Nitrile Gloves
  • Shop Towels

To learn more about tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your vehicle. 

To remove and install the front brake pads on your model year 2021 and newer RZR 200, follow these steps:

1. Park the vehicle on a flat, level surface and set the parking brake.

2. Begin by loosening the lug nuts with a 15mm socket with a breaker bar while the vehicle is on the ground, but do not remove them at this time.

3. Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques. 

4. Once safely elevated, remove the lug nuts and set aside. 

5. Remove the wheels and set aside. 

6. Loosen the two brake pad mounting fasteners on the back of the brake caliper.

7. Remove and retain the brake caliper mounting fasteners with a 10mm socket.

8. Carefully remove the caliper from the brake disc. Note: Ensure the caliper is supported with a wire hanger, rope or retention strap to avoid damaging the brake line.

9. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers until the piston does not move. Note: Brake fluid will be forced back into the master cylinder fluid reservoir and can cause it to overflow. Remove any excess fluid needed to prevent overflow and wipe up any spills promptly to prevent paint damage.

10. Remove and retain the two brake pad retaining fasteners from the caliper with a 4mm long Allen socket. Note: The inside fastener may not be able to be completely removed due to clearance conflicts with the brake line.

11. Slide the outer brake pad out of the caliper.

12. Repeat this process for the inner brake pad.

13. Inspect the brake pads for damage or wear and replace if necessary. The minimum thickness should be 0.180 inches (4.6 mm). A new brake pad is part number 2208176.

14. Slide the inner brake pad into the caliper and then repeat this process for the outer pad.

15. Loosely reinstall the two retained brake pad mounting fasteners.

16. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads. Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.

17. Align the caliper with the mounting holes on the hub and reinstall two retained caliper fasteners.

18. Torque the fasteners to 20 ft-lbs (27 Nm).

19. Torque the brake fasteners to 18 ft-lbs (24 Nm).

20. Reinstall the wheels on the vehicle and tighten the lug nuts until fully seated.

21. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torqueing. 

22. Once lowered, torque the lug nuts to 30 ft-lbs (40 Nm) in a crisscross pattern. 

23. Safely lower the vehicle completely. 

24. If the brake pads were replaced, the brake burnishing procedure should be completed by slowly bringing the vehicle up to 25 miles per hour and gradually applying the brakes until stopped. Repeat this procedure 10 times while ensuring the brakes have had sufficient time to cool between runs to prevent brake disc warping.

For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.

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