Required Tools and Supplies
- 5mm Allen Socket
- 10mm Socket
- 15mm Socket
- 19mm Socket
- Ratchet
- Torque Wrench
- Breaker Bar
- C-Clamp or Locking Pliers
- Silicone Grease
- Wire Hanger, Rope or Retention Strap
- Brake Caliper Mounting Fasteners
- Eye Protection
- 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 RANGER.
To remove and replace the rear brake pads on your RANGER XD 1500, follow these steps:
1. Park the vehicle on a flat, level surface, ensure it is in PARK and remove the key.
2. Loosen the lug nuts with a 19mm socket with breaker bar while the vehicle is on the ground but do not remove at this time.
3. Safely elevate the vehicle. Reference your Owner's Manual for proper lifting techniques.
4. Remove the lug nuts and set aside.
5. Remove the wheels and set aside.
6. Remove the brake pad adjuster screw with a 5mm Allen socket.
7. Remove the brake pad fastener with a 10mm socket.
8. Remove the upper and lower caliper mounting fasteners with a 15mm socket and remove the caliper from the knuckle. Discard the caliper mounting bolts. Note: When removing the caliper, use care not to damage the brake hose. Support the caliper to avoid kinking or bending the brake hose.
9. Use a C-clamp or locking pliers to slowly push against the outer brake pad and move the caliper piston into the caliper bore. Note: Break fluid will be forced through the compensating port into the master cylinder fluid reservoir when the piston is pushed back into the caliper. Remove the excess fluid from the reservoir as required.
10. Push the mounting bracket inward and slip the outer brake pad from between the bracket and caliper body.
11. Remove the outer brake pad from the caliper and then remove the inner brake pad.
12. Inspect the brake pads for damage or wear and replace, if necessary. The service limit is 0.03 inches (0.76 mm). New brake pads are part number 2211902.
13. Remove the mounting bracket from the caliper body.
14. Inspect the rubber dust boots for tears or damage and replace, if necessary.
15. Clean the mounting bracket pins with a shop rag to remove any old grease or debris.
16. To install rear brake pads, lubricate the mounting bracket pins with a light film of silicone grease and install the rubber dust boots.
17. Compress the mounting bracket and make sure the dust boots are fully seated and install the pads with the friction material facing each other. Note: If brake pads are contaminated with grease, oil or liquid soaked, do not use the pads. Use only new, clean pads.
18. Install the caliper onto the knuckle with new mounting fasteners, and torque to 37 ft-lbs (50 Nm).
19. Install the brake pad fasteners, and torque to 10 ft-lbs (14 Nm). Note: Replace fastener or apply blue Loctite® 242 to existing fastener.
20. Slowly pump the brake pedal until pressure has been built up. Maintain at least half inch (12.7 mm) of brake fluid in the reservoir to prevent air from entering the brake system.
21. Install the brake pad adjuster screw. Note: Make sure the brake pad adjuster screw head is flush with the machined surface. Over-tightening the screw will cause pad drag. After adjustment, make sure pads move freely.
22. Verify the fluid level in the reservoir is up to the MAX line inside the reservoir and install the cap.
23. Install the wheel 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 wheel in place when torquing.
25. Torque the lug nuts to 120 ft-lbs (163 Nm).
26. Field test your vehicle for proper braking action before putting back into service. Also inspect for fluid leaks and firm brakes. Make sure the brake is not dragging when the pedal is released. If the brake drags, re-check the assembly and installation.
27. If new brake pads were installed, it is required that a burnishing procedure be performed after installation to extend the service life and reduce noise.
28. To begin the procedure, start your vehicle and slowly increase speed to thirty miles per hour and gradually apply brakes to stop the vehicle. Then, allow pads and disc to cool sufficiently during the procedure. Do not let pads or disc to become hot or warping may result. Repeat this procedure ten times. Do not make more than three stops in one mile (1.6km).
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.
Unless noted, trademarks are the property of Polaris Industries Inc.
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