Brake Pedal; Brake Pedal Removal; Pedal Installation; Brake Pedal Inspection / Adjustment - Polaris RANGER RZR 170 Service Manual

BRAKE PEDAL

Brake Pedal Removal

1. Refer to Fig. 2 for pedal removal.
2. Disconnect both springs (A).
C
A B
3. Remove cotter pin (B) and clevis pin (C).
4. Remove E-clip (D) and washer (E) from pedal mount.
5. Remove pedal assembly with bushings (F) and sleeve
(G). Visually inspect pedal, bushings, and sleeve for
wear and replace as required.

Pedal Installation

1. Apply Polaris Premium All Season grease to pivot
post and install pedal with bushings and sleeve.
2. Install washer and a new retaining E-clip.
3. Align pedal with master cylinder clevis and install pin.
4. Install washer and a new cotter pin.
5. Connect brake light switch spring and pedal return
spring.
6. Push and release brake pedal to be sure linkage rod
and pedal mechanism returns fully when pedal is
released.
7. Inspect brake pedal travel. See "Brake Pedal
Inspection / Adjustment" on page 6.9.
Brake Pedal Travel:
1/2-3/4" (12-18mm)

Brake Pedal Inspection / Adjustment

1. Push and release brake pedal. Verify master cylinder
2. If pedal does not return freely, remove pedal and
F
Pedal Free Play and Pedal Travel
D
1. Place vehicle on a flat, level surface.
2. Shift transmission into Neutral.
3. Carefully lift rear tires off the ground with a stable
G
4. While rotating the rear wheels by hand, measure
E
5. Measure the total brake pedal movement before
6. The pedal should move at least 1/4 inch before any
7. If pedal travel is excessive, or if brake pedal feels
9923983 - 2012-2013 RZR 170 Service Manual
© Copyright 2012 Polaris Sales Inc.
actuator rod and pedal mechanism returns fully and
pedal contacts pedal stop (on left side of pedal pivot
bracket) when released.
lubricate. parts. See "Brake Pedal Removal" on
page 6.9.
platform jack, or set vehicle on stable jack stands.
brake pedal movement before any braking occurs
(Free Play), and record.
brake is firmly applied (Pedal Travel).
braking occurs, and no more than 1 - 1 1/2 inch before
brakes are firmly applied. See Fig.1. 
Pedal Travel
1 - 1 1/2 in. (25-37mm)
Fig. 1
1/4 in. (6mm) Minimum
spongy and not firm, inspect brake fluid level in the
reservoir, inspect system for leaks, inspect caliper
mounting bolts, disc mounting bolts to be sure they are
tight, and bleed the brake system. See "BRAKE
BLEEDING / FLUID CHANGE" on page 6.7.
BRAKES
6
6.9