Required Tools and Supplies
- 5mm Allen Socket
- 10mm Socket
- 15mm Socket
- 19mm Socket
- 21mm Socket
- 21mm Wrench
- Torque Wrench
- Breaker Bar
- C-Clamp or Locking Pliers
- Flat-Head Screwdriver
- High Temperature Grease
- Wire Hanger, Rope or Retention Strap
- Upper and Lower Caliper Mounting Bolts
- 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 inspect and replace the rear brakes on your RZR Turbo R, 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. 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. Loosen the pad adjuster screw with a 5mm Allen socket. Do not remove them.
4. Remove the caliper fasteners with a 10mm socket.
5. Remove and retain the lower radius rod fastener and nut, and position the rod out of the way.
6. Remove and discard the upper and lower caliper mounting bolts, and carefully remove the caliper from the rear hub. Use care to avoid damaging the brake line when removing the upper caliper fastener.
7. Carefully remove the caliper from the brake disc.
8. 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.
9. Squeeze the upper portion of the caliper mount 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 the clearance needed to remove the pads.
10. Disconnect the caliper mount from the caliper boots and slide the caliper mount off of the caliper.
11. Inspect the two caliper boots for tears or damage and replace as necessary.
12. Ensure the caliper is supported with a wire hanger, rope or retention strap to avoid damaging the brake line.
13. Clean the mount pins with a shop rag to remove any old grease or debris.
14. Lubricate the mount pins with a light film of high temperature grease.
15. Inspect the brake pads for damage or wear and replace if necessary. The minimum thickness is 0.030 inches (0.762mm).
16. Install the caliper mount pins into the two caliper boots, ensuring the boots are secured over the lip on the mount pin. To do this, press the caliper mount in and twist the boots while working them over the lip on the pins.
17. Push the mounting bracket inward and pivot the inner brake in between the bracket and caliper body. Repeat this for the outer pad as well.
18. Carefully slide the caliper assembly onto the brake disc, ensuring the brake rotor is between the two pads.
19. Align the caliper with the mounting holes on the hub and install two new caliper fasteners.
20. Torque the fasteners to 52 ft-lbs (70 Nm).
21. Ensure any items used to secure the brake caliper are removed from the wheel well.
22. Torque the caliper fasteners to 11 ft-lbs (15 Nm).
23. Tighten the set screw on the back side of the caliper and turn the screw until the pads touch the brake disc.
24. Loosen the set screw a half turn to allow the brake disc to move.
25. Align the radius rod with the mounting holes in the trailing arm, and torque the fasteners to 133 ft-lbs (180 Nm).
26. Install the wheels 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 148 ft-lbs (200 Nm) in a crisscross pattern.
29. Repeat this process for the other wheel.
30. Lower the vehicle completely.
31. Verify the fluid level in the reservoir is up to the MAX line inside the reservoir.
32. Slowly pump the brake pedal multiple times until pressure has been built up. Maintain at least half of the brake fluid reservoir to prevent air from entering the brake system.
33. 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.
34. 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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