Required Tools and Supplies
- 5mm Allen Socket
- 15mm Socket
- 19mm Socket
- Torque Wrench
- Breaker Bar
- C-Clamp or Locking Pliers
- Wire Hanger, Rope or Retention Strap
- All-Purpose Grease
- 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 remove and install the front brake pads on your RZR XP, follow these steps:
1. Park the vehicle on a flat, level surface and ensure it is in PARK.
2. Loosen the lug nuts while the vehicle is on the ground with a 19mm socket with breaker bar, 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 brake pad adjuster screw 2-3 turns counterclockwise with a 5mm Allen socket.
7. Remove and retain the upper and lower brake caliper mounting bolts with a 15mm socket.
8. Carefully remove the caliper from the brake disc. 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 with pads 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.
10. Push the mounting bracket inward and slip the outer brake pad out between the bracket and caliper body.
11. Repeat this process for the inner brake pad.
12. Place a catch pan under the brake caliper and remove the caliper.
13. Inspect the brake pads for damage or wear and replace if necessary. The minimum thickness should measure 0.03 inches (0.76 mm). New brake pads are part number 2211845.
14. Lubricate the mounting bracket pins with a light film of silicone grease and install the rubber dust boots.
15. Compress the mounting bracket and make sure the dust boots are fully seated.
16. Slide the inner brake pad into the caliper and then repeat this process for the outer pad. Install the pads with friction material facing each other.
17. 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.
18. Loosely reinstall the two retained brake pad mounting bolts.
19. Torque the two front caliper mounting bolts to 30 ft-lbs (41 Nm).
20. Slowly pump the brake pedal until pressure has been built up. Maintain at least 1/2 inch (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
21. Fasten the adjustment set screw and turn clockwise until the stationary pad contacts the disc, then back off 1/2 turn counterclockwise.
22. Verify that the fluid level in the reservoir is up to the MAX line inside the reservoir and install the reservoir cap.
23. Reinstall the wheels on the vehicle and tighten the lug nuts until fully seated.
24. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torquing.
25. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern.
26. Safely lower the vehicle completely.
27. If the brake 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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