Caliper Installation; Rear Brake Disc; Disc Inspection - Polaris 2011 RANGER RZR Service Manual

Caliper Installation

1. Install the rear caliper with the mounting bolts. Torque
mounting bolts to specification.
Rear Caliper Mount Bolt Torque:
18 ft. lbs. (24 Nm)
2. Install brake line banjo bolt and torque to specification.
3. Install the pad adjustment screw and turn until stationary
pad contacts disc, then back off 1/2 turn.
4. Follow bleeding procedure outlined earlier in this chapter.
5. Install wheel and torque wheel nuts to specification.
Wheel Nuts:
Steel Wheels: 27 ft. lbs. (37 Nm)
Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)
NOTE: If new pads are installed, refer to "REAR
BRAKE PADS - Brake Burnishing Procedure".
18 ft. lbs.
(24 Nm)
= T
15 ft. lbs.
(21 Nm)
= T
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.

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" (4.78 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)
BRAKES
Side
View
Measure
Thickness
9
9.23