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POLARIS GOVERNMENT & DEFENSE
HELP CENTER
9/18/2023

2024 RZR XP Wheel and Brake System Inspection and Tire Rotation

Required Tools and Supplies

  • 19mm Socket
  • Torque Wrench
  • Breaker Bar
  • Brake Rotor Measurement Tool
  • Brake Pad Measurement Tool
  • Tire Pressure Gauge
  • Tread Depth Gauge
  • Flashlight
  • Shop Rags
  • Safety Glasses
  • Nitrile Gloves

For information on tools, read the Tools and Fasteners Guide. Always wear safety glasses and nitrile gloves when servicing your Polaris RZR.

To Inspect the wheels and brake system and perform a tire rotation on your RZR XP, follow these steps. 

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

2. 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.
  • 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.
  • Take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.

3. Inspect the fluid level and condition in the master cylinder. 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 of brake fluidNote: Do not allow brake fluid to contact painted surfaces or paint damage may occur.

4. Remove the wheels from the vehicle. 

  • Loosen the lug nuts with a 19mm socket before the vehicle is off the ground, but do not remove them.
  • 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. 

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

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

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

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

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

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

11. If inspection reveals any concerns, do NOT attempt to drive the vehicle. See your authorized Polaris Service Center.

12. Take a look at the brake pads and rotors. Note: 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. Replace any brake pads that are worn beyond their minimum thickness. The minimum thickness is 0.030 inches (0.762mm). New front brake pads are part number 2211845. New rear brake pads are part number 2211852.
  • Use a brake rotor measuring tool to measure the thickness of the brake rotors. Replace the rotors if they are worn below the minimum thickness. The minimum thickness is 0.170 inches (4.32 mm). New brake discs are part number 5257196

13. 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.

14. 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 torquing. 
  • Once lowered, torque the lug nuts to 120 ft-lbs (163 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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