Pad Assembly / Installation; Brake Burnishing Procedure - Polaris xp 2013 eps Service Manual

BRAKES

Pad Assembly / Installation

1. Lubricate mounting bracket pins with a light film of
silicone grease and install rubber dust boots.
Apply Grease to Each
Bracket Pin
2. Compress mounting bracket and make sure dust
boots are fully seated. Install pads with friction
material facing each other.
If brake pads are contaminated with grease, oil,
or liquid soaked do not use the pads.
Use only new, clean pads.
3. Install caliper onto front hub and torque mounting
bolts to specification.
Front Caliper Mount Bolt:
40 ft-lbs (54 Nm)
9.16
WARNING
40 ft-lbs
(54 Nm)
= T
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
4. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2" (12.7 mm) of brake fluid
in the reservoir to prevent air from entering the brake
system.
5. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
6. Verify fluid level in reservoir is up to MAX line inside
reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
7. Install wheel and torque wheel nuts to specification.
Wheel Nuts:
30 ft-lbs (41 Nm) + 90° (1/4 turn)

Brake Burnishing Procedure

It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
1/2 Turn
= T