Brake Burnishing Procedure; Rear Brake Disc; Disc Inspection; Rear Brake Disc Replacement - Polaris RZR 170 2009 Service Manual

BRAKES
8. Verify fluid level in reservoir is up to the MAX line inside
reservoir and install reservoir cap.
Master Cylinder Fluid
Up to MAX line inside reservoir
9. Install wheel and torque wheel nuts.
Rear Wheel Nut Torque:
27 ft. lbs. (37 Nm)

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 25 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.

REAR 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" micrometer and measure the disc thickness at
eight different points around the pad contact surface.
Replace disc if worn beyond service limit.
X
X
X
X
X
X
Brake Disc Thickness
New: .160" (4.05 mm)
Service Limit: .138" (3.50 mm)
6.18
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X
X
Side
View
Measure
Thickness
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 specifications.
Brake Disc Runout
Service Limit .010" (.254 mm)

Rear Brake Disc Replacement

1. Remove rear brake caliper. See "Rear Brake Pad
Removal" on page 6.15.
2. Refer to Rear Axle Removal (Chapter 5) to replace the rear
brake disc.
Rear Brake Disc:
21 ft. lbs. (28.5 Nm)
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
3. Install rear brake caliper. See "Rear Brake Pad Assembly /
Caliper Installation" on page 6.17.
4. 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.
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CAUTION