This procedure requires use of brake fluid. Purchase brake fluid here
|Required Tools and Supplies|
|Brake Fluid||Safety Glasses & Nitrile Gloves|
|Shop Rags||Torque Wrench|
|Breaker Bar||Brake Pad Measurement Tool|
|Brake Rotor Measurement Tool||19mm Socket|
For more information, read Tools and Fasteners Guide.
Always wear safety glasses and nitrile gloves while servicing your Polaris RZR.
To perform a brake inspection and to inspect and rotate your tires on your RZR Pro XP or RZR Pro XP 4, follow these steps:
1. Take a close look at each tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
- Inspect for damage that may compromise the integrity of the tire.
- Next, inspect the tire pressure and verify it is set to specification. Tire pressure should be 10 psi (69 kPa) for front tires and 20 psi (138 kPa) for rear tires.
- Lastly, take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. Tires should be rotated side to side on the same axle.
- Using a 19mm socket, loosen the lug nuts while the vehicle is on the ground. Do not remove. Caution: Do not remove the lug nuts before the vehicle is safely elevated. Doing so may cause the vehicle to tip and may cause serious injury or death.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Remove the lug nuts and set aside.
- Then remove the wheels and set aside.
3. Before rotating the tires, it’s a great time to look at the brake system.
- Start at the front of the vehicle on the driver’s side near the master cylinder. Inspect the fluid level and condition in the master cylinder. Ensure the level is between the minimum and maximum marks. Add fluid as necessary. DOT 4 Brake Fluid is part number 2872189. Caution: After opening a bottle of brake fluid, always discard any unused portion. Brake fluid rapidly absorbs moisture from the air, which causes the boiling temperature to drop. This can lead to early brake fade and the possibility of an accident or serious injury.
- Look at the banjo bolts on the right side of the master cylinder and inspect for leaks. Tip: Use a mirror to see the banjo bolts.
- Follow the lines all the way to both front calipers, looking for any leaks, kinks or damage. Also, ensure the brake line retainers are properly secured.
- Inspect the connections at the front brake calipers for leaks.
- Next, follow the brake lines to the rear of the vehicle, checking for leaks, kinks and damage.
- Inspect the connections at the junction block in the driver’s rear wheel well.
- Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Also ensure the brake line retainers are properly secured.
- Inspect the rear brake calipers and connections for leaks.
- If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
4. Next take a look at the brake pads and rotors. Caution: Brake rotors can become extremely hot after operation. Allow the rotors to cool completely before proceeding to prevent the risk of burns.
- Check the brake pad thickness using a suitable tool. Be sure to check the inside and outside pads. Replace any brake pads that are worn beyond their minimum thickness of 0.180 inches (4.6mm).
- Use a brake rotor measuring tool to measure the thickness of the brake rotors and replace if worn below the minimum thickness of 0.268 inches (6.8mm).
5. Once the brake system inspection has been completed, the tires can be rotated and reinstalled. Rotate the wheels as needed, based on wheel configuration. Caution: 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.
- Install the wheels on the vehicle and hand tighten the lug nuts.
- Safely lower the vehicle until the tires begin to touch the ground. Reference your Owner’s Manual for proper lowering techniques.
- Torque the lug nuts to 120 ft-lbs (162.7 Nm) in a crisscross pattern.
- 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.
© 2022 Polaris Industries Inc.