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POLARIS OFF-ROAD VEHICLES
CENTRE D'AIDE
8/25/2023

2021+ RZR Trail and Trail S Brake Pad Removal and Installation

Required Tools and Supplies

  • T30 TORX® Socket
  • 5mm Allen Socket
  • 15mm Socket
  • 19mm Socket
  • 15mm Crow Foot
  • Torque Wrench
  • Breaker Bar
  • C-Clamp or Locking Pliers
  • Wire Hanger, Rope or Retention Strap
  • Brake Cleaner
  • High Temperature Grease
  • Caliper Fasteners
  • 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 brake pads on your RZR Trail or Trail S, follow these steps:

1. Park the vehicle on a flat, level surface and ensure it is in PARK.

2. Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground, 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 wheel and set aside. 

6. Remove and retain the front brake shield fasteners with a T30 TORX® socket, and set the brake shield aside.

7. Loosen the pad adjuster screw two to three turns with a 5mm Allen socket.

8. Remove and discard the caliper mounting fastener with a 15mm socket or wrench. Note: The lower caliper fastener on the rear axle has limited access and will require a box wrench.

9. 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.

10. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers until the piston does not move. 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. Push the mounting bracket inward and pivot the outer brake pad out between the bracket and caliper body. Repeat this for the inner pad as well. Tip: If the brake pads are difficult to remove, ensure the pad adjuster screw is loosened far enough to create clearance for the pads to be removed.

12. Disconnect the caliper mount from the caliper boots and slide the caliper mount off the caliper.

13. Inspect the two caliper boots for tears or damage and replace as necessary.

14. Clean the mount pins with a shop rag and brake cleaner to remove any old grease or debris.

15. Lubricate the mount pins with a light film of high temperature grease. 

16. Inspect the brake pads for damage or wear and replace if necessary. The minimum thickness should measure 0.040 inches (1 mm). New front brake pads are part number 2206025.

17. 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, pinch the boots and twist while working them over the lip on the pins.

18. Push the mounting bracket inward and pivot the inner brake in between the bracket and caliper body. Repeat this for the other pad as well.

19. 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.

20. Align the caliper with the mounting holes on the hub and install two new caliper fasteners.

21. Torque the fasteners to specification: front caliper fasteners - 30 ft-lbs (42 Nm) and rear caliper fasteners – 46 ft-lbs (62 Nm). Note: The lower caliper fastener on the rear axle has limited access and will require a crow foot to torque.

22. Tighten the set screw on the back side of the caliper, and turn the screw until the pads touch the brake disc. 

23. Loosen the set screw a half turn to allow the brake disc to move. 

24. Align the brake shield with the mounting holes on the caliper, and reinstall the retained shield fasteners.

25. Torque the fasteners to 84 in-lbs (9.5 Nm) and repeat this process for the other brake pads. Brake pads should be replaced in pairs on the same axle.

26. Reinstall the wheel on the vehicle and tighten the lug nuts until fully seated. 

27. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheels in place when torqueing. 

28. Once lowered, torque the lug nuts to specification in a crisscross pattern: steel wheels to 60 ft-lbs (81 Nm) and aluminum wheels to 120 ft-lbs (163 Nm).

29. Lower the vehicle completely.

30. 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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© 2023 Polaris Industries Inc.

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