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Rear Brake Disc; Disc Inspection; Disc Replacement - Polaris RZR XP 1000 Service Manual

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BRAKE SYSTEM

REAR BRAKE DISC

Disc Inspection

1. Visually inspect disc for scoring, scratches, or
gouges. Replace disc if deep scratches are evident.
2. Use a 0-1" micrometer and measure disc thickness
at eight different points around the pad contact
surface. Replace disc if worn beyond service limit.
Brake Disc Thickness
New: 0.188" (4.78 mm)
Service Limit: 0.170" (4.32 mm)
Brake Disc Thickness Variance
Service Limit: 0.002" (0.051 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
specifications.
Brake Disc Runout:
Service Limit: 0.010" (0.254 mm)
9.38
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.

Disc Replacement

1. Remove rear brake caliper (see Chapter 9 – Caliper
Removal, page 9.34).
2. Remove wheel hub cotter pin
washers
.
3. Remove the hub assembly from the vehicle and
remove the four bolts
4. Clean the wheel hub mating surface and install new
disc on wheel hub.
5. Install new bolts ⑤ and torque to specification.
CAUTION
Always use new brake disc mounting bolts. The bolts
have a pre-applied locking agent which is destroyed
upon removal.
Brake Disc Mounting Bolts:
30 ft-lb (41 Nm)
, castle nut
retaining the disc to the hub.
1
and

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Rzr xp4 1000