Caliper Disassembly / Inspection; New Brake Pad Installation - Polaris xp 2013 eps Service Manual

Caliper Disassembly / Inspection

NOTE: Refer to the "Electronic Parts Catalog" for
parking brake caliper replacement parts information.
1. Remove the two caliper assembly bolts (C).
2. Slide the brake pads and springs from the assembly.
NOTE: Retain the lever and ball bearings for
reassembly.
3. Inspect brake pads for excessive wear. Replace as
needed.
4. Check the three steel balls for any signs of cracking.
Replace as needed.
5. Check ball seats in lever and stationary actuator. If
excessively worn, replace parts as needed.
6. Measure thickness of the rear caliper parking brake
pads. Replace assembly or pads as needed. Refer to
the following image for brake pad specifications.
Outboard Pad Thickness
New 0.250" (6.35 mm)
Limit: 0.190" (4.83 mm)
C
Outboard Inboard
Pad Pad
Inboard Pad Thickness
New 0.300" (7.62 mm)
Limit: 0.240" (6.10 mm)
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.

New Brake Pad Installation

1. Install new pads and assemble the caliper with one
shim. For shim location, see Figure 9.1 on page 9.11.
2. Measure gap for the brake disc and compare to gap
specification. Disassemble and add shim(s) between
thrust washer and the inside brake pad as needed to
close the gap to .207-.217 in. (5.25-5.51 mm).
Add shims until gap
measures .207"-.217"
(5.25-5.51 mm)
3. Once you have determined the correct amount of
shims to use, reassemble the caliper and apply an
Anti-Seize Lubricant to the thrust washer and shims.
4. Torque the caliper assembly bolts to specification.
Parking Brake Caliper - Assembly Bolts:
37 ft-lbs (50 Nm)
5. Ensure the parking brake assembly functions properly
by actuating the lever. Install the mounting sleeves (D)
before installation.
BRAKES
= T
D
9.13
9