Required Tools and Supplies
- 5mm Allen Socket
- 10mm Socket
- 15mm Socket
- 10mm Wrench
- 19mm Socket with Breaker Bar
- Torque Wrench
- Ratchet
- C-Clamp or Locking Pliers
- 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 rear brake pads on your RZR XP, follow these steps:
1. Park the vehicle on a flat, level surface.
2. Loosen the lug nuts while the vehicle is on the ground with a 19mm socket with a 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 pad adjuster screw 2-3 turns counterclockwise with a 5mm Allen socket.
7. Remove the brake line cover bolts and brake line cover with a 10mm socket and 10mm wrench, and set aside.
8. Remove the two caliper mounting bolts with a 15mm socket, and carefully lift the caliper off 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 caliper mounting bracket inward and slide the outer brake pad past the edge to remove. Repeat this process for the inner pad.
11. Inspect the brake pads for damage or wear and replace if necessary. Measure the brake pads with a brake pad measuring tool. Its minimum thickness is 0.03 inches (0.76 mm).
12. Lubricate the mounting bracket pins with a light film of silicone grease and install the rubber dust boots.
13. Compress the mounting bracket and make sure the dust boots are fully seated.
14. Carefully install the pads with friction material facing each other. Slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads.
15. Torque the new mounting bolts to 52 ft-lbs (70 Nm). Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.
16. Slowly pump the brake pedal until pressure has been built up. Maintain brake fluid in the reservoir between the MIN and MAX lines to prevent air from entering the brake system.
17. Install the adjustment set screw and turn clockwise until the stationary pad contacts the disc, then back off half turn counterclockwise.
18. Verify the fluid level in the reservoir is up to the MAX line inside the reservoir and install the reservoir cap.
19. Install the brake line cover, and torque the bolts to 7 ft-lbs (10 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 torquing.
22. Once lowered, torque the lug nuts to 120 ft-lbs (163 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 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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