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

2021+ RZR 200 EFI Rear Brake Pad Removal and Installation

Required Tools and Supplies

  • 4mm Allen Socket
  • 10mm Socket
  • Torque Wrench
  • Flat-Head Screwdriver
  • 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 rear brake pads on your model year 2021 and newer RZR 200, follow these steps:

1. Park the vehicle on a flat, level surface and chock the front wheels.

2. Remove and retain the two brake caliper mounting fasteners.

3. Carefully remove the caliper from the brake disc. 

4. Remove and retain the two brake pad mounting fasteners from the caliper.

5. Slide the outer brake pad out of the caliper and repeat this process for the inner pad.

6. 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 2209841.

7. Screw the caliper piston into the caliper bore slowly with a flat-head screwdriver. 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.

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

9. Reinstall the two retained brake pad mounting fasteners, and torque the fasteners to 35 ft-lbs (48 Nm).

10. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads.

11. Align the caliper with the mounting holes on the chassis and reinstall the two retained caliper fasteners.

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

13. 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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