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POLARIS GOVERNMENT & DEFENSE
HELP CENTER
2/12/2024

2024 RANGER XD 1500 Wheel and Brake System Inspection and Tire Rotation

Required Tools and Supplies

  • 19mm Socket
  • Breaker Bar
  • Torque Wrench
  • Brake Pad Measurement Tool
  • Tire Pressure Gauge
  • Tread Depth Gauge
  • Flashlight
  • Brake Fluid
  • Eye Protection
  • Nitrile Gloves
  • Shop Rags

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

To inspect the wheels and brake system and perform a tire rotation on your RANGER XD 1500, follow these steps:

1. Ensure the vehicle is on a flat, level surface and in PARK.

2. Turn the key switch OFF and remove the key.

3. Take a close look at each tire. 

  • Inspect for damage that may compromise the integrity of the tire.
  • Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
  • 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.

4. View the brake fluid level in the reservoir in the driver’s side wheel well. The level should be between the upper (MAX) and lower (MIN) level lines. Ensure the level is between the min and max marks. 

5. If the fluid level is lower than the upper-level line, access the brake fluid reservoir through the hood and add brake fluid as needed. Note: Do not allow brake fluid to contact painted surfaces, or paint damage may occur. Brake fluid is part number 2872189.

6. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

7. Remove the tires from the vehicle.

  • Loosen the lug nuts by using a 19mm socket with breaker bar before the vehicle is off the ground. Do not remove at this time.
  • Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
  • Remove the lug nuts and set aside. 
  • Remove the wheels and set aside. 

8. Inspect the banjo bolts on the passenger side of the master cylinder for leaks. Tip: A mirror and flashlight can be used to help see the bolts. 

9. Follow the lines all the way to the front calipers, looking for any leaks, kinks or damage. Ensure the brake line retainers are properly secured.

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

11. Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Ensure the brake line retainers are properly secured.

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

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

14. Take a look at the brake pads. 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 of 0.030” inch (.762 mm). Repeat on the other side. New front brake pads are part number 2209570. New rear brake pads are part number 2211902.

15. Once the brake system inspection has been completed, the tires can be rotated, if applicable, and reinstalled. 

16. Rotate the wheels as needed based on wheel configuration. Note: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to the markings and directional indicators on the tires. 

  • Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
  • Attach the wheel nuts and tighten until snug.
  • Carefully lower the vehicle to the ground.
  • Torque the wheel nuts to 120 ft-lbs (163 Nm) in a star pattern using a non-impact torque tool. Use the correct size wheel nut socket and do not exceed the wheel nut recommended torque value. 

For more information, see your authorized Polaris Dealer. To find a dealer near you, use 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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