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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
9/8/2023

2021+ RZR 200 EFI Wheel and Brake System Inspection and Tire Rotation

Required Tools and Supplies

  • 15mm Socket
  • Torque Wrench
  • Brake Rotor Measurement Tool
  • Brake Pad Measurement Tool
  • Tire Pressure Gauge
  • Tread Depth Gauge
  • Breaker Bar
  • Flashlight
  • Brake Fluid
  • 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 inspect the wheels and brake system and perform a tire rotation on your model year 2021 and newer RZR 200, follow these steps:

1. Take a close look at each tire. 

  • Verify there is sufficient tread depth. Tires should be replaced once they reach 1/8 inch or 3mm of tread depth.
  • Inspect for damage that may compromise the integrity of the tire.
  • Inspect the tire pressure and verify it is set to specification. Reference the Owner’s Manual or tire pressure label on your vehicle for the correct specification.
  • Lastly, take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.

2. Inspect the fluid level and condition in the master cylinder through the front grille. Ensure the level is between the min and max marks. If it is low, clean around the cap and add fluid as necessary from a new and unopened bottle. Warning: Do not allow brake fluid to contact painted surfaces or paint damage may occur.

3. Remove the wheels from the vehicle. 

  • 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 it 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. 

4. Inspect the banjo bolts on the passenger side of the master cylinder for leaks. Tip: A flashlight can be used to help see the bolts. 

5. Follow the lines all the way to the front calipers, looking for any leaks, kinks or damage. Also ensure the brake line retainers are properly secured.

6. Inspect the connections at the front brake calipers for leaks.

7. Follow the brake lines back to the rear of the vehicle, checking for leaks, kinks and damage. 

8. Follow the brake line to the rear brake caliper, looking for leaks, kinks and damage. Also ensure the brake line retainers are properly secured.

9. Inspect the rear brake caliper and connection for leaks. 

10. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris service center.

11. Look at the brake pads and rotors. Warning: Always allow the brakes to cool completely before inspecting to prevent the risk of burns.

  • Check the brake pad thickness using a suitable tool. Be sure to check the thickness on the inside pads as well and replace any brake pads that are worn beyond their minimum thickness. The pads can also be inspected by observing the wear indicators. Replace any that are worn to the indicator groove at 0.180 inches (4.6 mm). 
  • Use a brake rotor measuring tool to measure the thickness of the brake rotors and replace any rotors that are worn below the minimum thickness. of 0.138 inches (3.50 mm). 

12. Once the brake system inspection has been completed, the tires can be rotated and reinstalled. Note: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to all markings and directional indicators on the tires. 

13. Rotate the wheels as needed based on wheel configuration. 

  • Ensure the valve stem is facing toward the outside of the vehicle and install the wheels on the vehicle. Tighten the lug nuts until fully seated.
  • Once installed, safely lower the vehicle until the tires begin to touch the ground. This will help keep them in place when torqueing. 
  • Once lowered, torque the lug nuts to 30 ft-lbs (41 Nm) in a crisscross pattern. 
  • Finally, lower the vehicle completely.

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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