Required Tools and Supplies
- 6mm Allen Socket
- 16mm Socket
- 19mm Socket
- 21mm Socket
- 21mm Wrench
- Torque Wrench
- Breaker Bar
- C-Clamp or Locking Pliers
- Flat-Head Screwdriver
- High Temperature Grease
- Wire Hanger, Rope or Retention Strap
- Tie Rod Nut
- Upper and Lower Caliper Mounting Bolts
- Safety Glasses
- Nitrile Gloves
- Shop Towels
For information on tools, read the Tools and Fasteners Guide.
Always wear safety glasses and nitrile gloves when servicing your Polaris RZR. To inspect and replace the front brakes on your RZR Turbo R, follow these steps:
1. Park the vehicle on a flat, level surface and ensure it is in PARK.
2. Remove the tires from the vehicle.
- Loosen the lug nuts with a 19mm socket with a breaker bar while the vehicle is on the ground. Do not remove them at this time.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Once safely elevated, remove the lug nuts and set aside.
- Remove the wheels and set aside.
3. Loosen the tie rod nut on the bearing carrier with a 21mm socket until the ball joint stem is recessed.
4. Strike the tie rod nut firmly to free the tie rod from the carrier. Warning: Use care to avoid damaging the brake line or banjo bolt on the brake caliper.
5. Remove and retain the washer. Discard the nut.
6. Pull the tie rod end out of the hub.
7. Remove and discard the upper and lower caliper mounting bolts and carefully remove the caliper from the bearing carrier with a 16mm socket. Use care to avoid damaging the brake line when removing the upper caliper fastener.
8. Rest the caliper upside down on the wheel hub.
9. Carefully press in on the outer brake pad to remove it from the caliper.
10. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers with the inner pad installed. 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.
11. Pull the inner pad away from the caliper bore and pivot out to remove the pad.
12. Turn the caliper on its side and slide the caliper mounting bracket off the caliper.
13. Inspect the caliper boots for wear or damage and replace if necessary.
14. Support the caliper with a wire hanger, rope or retention strap to avoid damage by kinking or bending the line.
15. Inspect the brake pads for damage or wear and replace if necessary. The minimum thickness is 0.030 inches (0.762 mm).
16. Remove the brake pad clips from the caliper mounting bracket and inspect for any wear or damage. Replace if necessary. Tip: A flat-head screwdriver may be used to aid in removal.
17. Clean the caliper mounting bracket stems with a shop rag.
18. Apply high temperature grease to the stems.
19. Reinstall the brake pad clips into the caliper bracket.
20. Install the caliper mount pins into the two caliper boots. Ensure the boots are secured over the lip on the mount pin. To do this, press the caliper mount in and twist the boots while working them over the lip on the pins.
21. Lubricate the outside edges of the inner pad, install the pad on the caliper and press in until fully seated.
22. Lubricate the outside edges of the outer pad, reinstall the pad and hook one side of the pad in first and then rotate the other hook into place.
23. Install the caliper onto the brake disc, ensuring there is one pad on each side of the brake disc.
24. Align the mounting holes and install the new upper and lower caliper fasteners. Use care to avoid damaging the brake line when reinstalling the upper caliper fastener.
25. Torque the fasteners to 74 ft-lbs (100 Nm).
26. Ensure any items used to secure the brake caliper are removed from the wheel well.
27. Inspect the tie rod for wear or damage and replace if necessary.
28. Insert the tie rod into the bearing carrier and secure with the retained washer and a new nut.
29. Counter hold the ball joint stem with a 6mm Allen and 21mm socket, and torque the nut to 52 ft-lbs (70 Nm) plus 90 degrees.
30. Install the wheels on the vehicle and tighten the lug nuts until fully seated.
31. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torqueing.
32. Once lowered, torque the lug nuts to 148 ft-lbs (200 Nm) in a crisscross pattern.
33. Repeat this process for the other wheel.
34. Lower the vehicle completely.
35. Verify the fluid level in the reservoir is up to the MAX line inside the reservoir.
36. Slowly pump the brake pedal multiple times until pressure has been built up. Maintain at least half of the brake fluid reservoir to prevent air from entering the brake system.
37. Repeat this process for the brake pads on the other side of the vehicle as needed. Always replace brake pads in pairs on the same axle.
38. If the pads were replaced, the brake burnishing procedure should be completed by slowly bringing the vehicle up to 30 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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