Rear Brake Disc; Disc Inspection; Disc Replacement - Polaris 2008 RZR Service Manual

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.
Front
View
Brake Disc Thickness
New: .188" (4.76 mm)
Service Limit: .170" (4.32 mm)
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)

Disc Replacement

1. Remove rear brake caliper (see "REAR CALIPER
SERVICE").
2. Remove wheel hub cotter pin, castle nut and washers.
3.
Side
View
4.
5.
Measure
Thickness
6.
7.
8.
Remove the hub assembly from the vehicle and remove the
(4) bolts retaining the disc to the hub.
Cotter
Pin
Washers
Nut
Clean the wheel hub mating surface and install new disc on
wheel hub.
Install new bolts and torque to 28 ft. lbs. (38 Nm).
CAUTION
Always use new brake disc mounting bolts. The
bolts have a pre-applied locking agent which is
destroyed upon removal.
Install wheel hub assembly, washers, and castle nut.
Torque castle nut to 80 ft. lbs. (108 Nm) and install a new
cotter pin.
Install rear brake caliper (see "REAR CALIPER
SERVICE"). Follow the bleeding procedure outlined
earlier in this chapter.
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.
BRAKES
(4) Bolts
28 ft. lbs.
(38 Nm)
9
9.19