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

2023+ RANGER XP Kinetic Brake Pad Removal and Replacement

Required Tools and Supplies

  • 5mm Allen Socket
  • 15mm Socket
  • 19mm Socket
  • 15mm Wrench
  • 15mm Crowfoot Wrench
  • Ratchet
  • Torque Wrench
  • Breaker Bar
  • C-Clamp or Locking Pliers
  • High Temperature Grease
  • Wire Hanger, Rope or Retention Strap
  • Brake Caliper Mounting Fasteners
  • 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 Polaris RANGER. To help inspect more of your brake system, read 2023 RANGER XP Kinetic Wheels and Brake System Inspection and Tire Rotation.

To remove and replace the brake pads on your RANGER XP Kinetic, 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, but 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. On the caliper, loosen the pad adjustment screw with a 5mm Allen socket, but do not remove it.

4. Remove and discard the upper and lower caliper mounting fasteners with a 15mm socket for the front and a 15mm wrench for the rear.

5. Carefully remove the caliper from the hub and support it with a wire hanger, rope or retention strap to avoid damaging the brake line.

6. Push the caliper piston into the caliper bore slowly, using a C-clamp or locking pliers with the pads installed, until the piston does not move. Note: Brake fluid will be forced back into the master cylinder fluid reservoir. Remove excess fluid as needed to prevent overflow. Also, remember to clean up any brake fluid promptly to prevent paint damage.

7. Push the mounting bracket inward to work both ends of the brake pad off the mounting pins equally, and slip the outer brake pad out between the bracket and caliper body.

8. Remove both springs from the caliper mounting bracket.

9. Remove the inner pad using the same process as the outer pad removal. 

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

11. Inspect the two caliper boots for tears or damage and replace as necessary. New boots are part number 5412506.

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

13. Lubricate the mount pins thoroughly with high temperature grease.

14. Inspect the brake caliper springs for wear or damage and replace if necessary. New springs are part number 7045868.

15. Inspect the brake pads for wear or damage and replace if necessary or worn to their minimum thickness, 0.03 inches (0.76 mm). New front brake pads are part number 2209279, and new rear brake pads are part number 2209280Note: Do not reuse pads if contaminated with grease and oil or if soaked with liquid.

16. Install the caliper mount pins into the two caliper boots, ensuring the lip is fully seated over the lips on the caliper and bracket. To do this, pinch the boots and twist to work them over the lips.

17. Install the inner brake pad onto both mount pins at once and press the pad in until fully seated.

18. Reinstall the two springs onto the mounting brackets.

19. Reinstall the outer brake pad using the same process as the inner pad.

20. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads. Note: Before continuing, ensure any items used to secure the brake caliper are removed from the wheel well.

21. Install new upper and lower caliper mounting fasteners. Torque the front to 27-30 ft-lbs (37-41 Nm), and torque the rear to 46 ft-lbs (62 Nm) with a 15mm crowfoot wrench.

22. Slowly pump the brake pedal until pressure has been built up. Maintain at least half of the brake fluid reservoir to prevent air from entering the brake system.

23. On the brake caliper, tighten the pad adjustment screw clockwise until the stationary pad contacts the disc and then loosen it a half turn counterclockwise.

24. Verify that the fluid level in the reservoir is up to the MAX line inside the reservoir.

25. Install the wheel on the vehicle, and tighten the lug nuts until fully seated.

26. 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.

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

28. Once lowered, torque the lug nuts to 120 ft-lbs (163 Nm) in a crisscross pattern. 

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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