Required Tools and Supplies
- 14mm 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 front 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. Remove the wheel from the vehicle.
3. Loosen the lug nuts while the vehicle is on the ground with a 9mm socket with breaker bar but do not remove at this time.
4. Safely elevate the vehicle. Reference your Owner's Manual for proper lifting techniques.
5. Remove the lug nuts and set aside.
6. Remove the wheels and set aside.
7. Remove the brake caliper fasteners with a 14mm socket.
8. Remove the caliper from the front knuckle. 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. Remove the brake pads.
10. Inspect the brake pads for damage or wear and replace, if necessary. The service limit is 0.03 inches (0.76mm).
11. If installing new pads, remove the brake pad retaining clips and inspect for any wear or damage. Replace, if necessary. New brake pads are part number 2209570.
12. Remove the brake caliper pins and clean with a shop rag.
13. Inspect the rubber dust boots for tears or damage and replace, if necessary.
14. Use a C-clamp or locking pliers, slowly push against the brake pad and move both caliper pistons into the caliper. Note: Brake fluid will be forced through the compensating port into the master cylinder fluid reservoir when the piston is pushed back into the caliper. Remove excess fluid from the reservoir as required.
15. Lubricate the caliper pins with a light film of silicone grease and install making sure the boots seat to caliper pins.
16. Install the brake pad mounting clips.
17. Install the pads into the caliper mounting bracket. Note: If brake pads are contaminated with grease, oil or liquid soaked, do not use the pads. Use only NEW, clean pads.
18. Slide the caliper onto the caliper mounting bracket.
19. Install the caliper onto the knuckle with the new mounting fasteners. Torque to 37 ft-lbs (50 Nm).
20. Slowly pump the brake pedal until pressure has been built up. Maintain at least a half-inch (12.7 mm) of brake fluid in the reservoir to prevent air from entering the system.
21. Verify the fluid level in the reservoir is up to the MAX line inside the reservoir and install the cap.
22. Install the wheel on the vehicle and tighten the lug nuts until fully seated.
23. Safely lower the vehicle until the tires begin to touch the ground. This will help keep the wheel in place when torquing.
24. Torque the lug nuts to 120 ft-lbs (163 Nm).
25. 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.
26. 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.
27. To begin the procedure, start your vehicle and slowly increase speed to thirty miles per hour and gradually apply brakes to stop the vehicle. 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 (1.6 km).
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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