Front Brake Disc; Disc Inspection; Disc Replacement - Polaris RZR 170 2009 Service Manual

FRONT BRAKE DISC

Disc Inspection

1. Visually inspect disc for scoring, scratches, or gouges.
Replace the disc if any deep scratches are evident.
2. Use a 0-1" (0-25mm) micrometer to measure disc thickness
at multiple locations around pad contact surface. Replace
disc if worn beyond service limit at any measurment point.
X
X
Brake Disc Thickness
New: .160 (4.05 mm)
Service Limit: .138" (3.50 mm)
Brake Disc Thickness Variance
Service Limit .002" (.051 mm)
difference between measurements
3. Mount a dial indicator and measure disc runout. Slowly
rotate the disc and read total runout on the dial indicator.
Replace the disc if runout exceeds service limit.
Brake Disc Runout
Service Limit .010" (.254 mm)
X
X
X
X
X
X

Disc Replacement

1. Remove front wheel and brake caliper. See "Front Pad
Removal" on page 6.11.
2. Remove hub assembly. Refer to Chapter 5.
3. Remove (6) bolts and disc from hub.
7 ft. lbs. (9.5 Nm)
4. Clean the wheel hub mating surface and install new disc on
wheel hub.
5. Install new bolts and torque to 7 ft. lbs. (9.5 Nm).
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
6. Install wheel hub assembly. Refer to Chapter 5.
7. Install front brake caliper (See "Front Brake Pad Assembly
/ Caliper Installation" on page 6.12.) and pump brake pedal
to regain pressure and set pads against disc.
8. Field test unit for proper braking action before putting into
service. Inspect for fluid leaks and firm brakes. Make sure
the brake is not dragging when pedal is released. If the brake
drags, re-check assembly and installation.
BRAKES
6
6.13