Polaris 2011 RANGER RZR, Service Manual

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9.21
BRAKES
9
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.
Caliper Disassembly
1. Remove brake pad adjustment set screw (K).
2. Push upper pad retainer pin inward and slip brake pads past
the edge and remove from the caliper.
3. Remove mounting bracket (B) and dust boots (G) and (H).
4. Using a hammer and a small punch, remove the piston (C)
from the caliper body (D). Remove the square O-rings (E)
and (F) from the caliper body (D).
5. Clean the caliper body, piston, and retaining bracket with
brake cleaner or alcohol.
NOTE: Be sure to clean seal grooves in caliper
body.
Caliper Inspection
1. Inspect caliper body for nicks, scratches or wear. Measure
bore size and compare to specifications. Replace if damage
is evident or if worn beyond service limit.
2. Inspect piston for nicks, scratches, wear or damage.
Measure diameter and replace if damaged or worn beyond
service limit.
H
G
C
K
D
B
Pads
F
E
Clean Components
= In. / mm.
RZR / RZR S: Rear Caliper Piston Bore I.D.
Standard: 1.191” (30.25 mm)
Service Limit: 1.192” (30.28 mm)
= In. / mm.
RZR 4: Rear Caliper Piston Bore I.D.:
Standard: 1.505” (38.23 mm)
Service Limit: 1.507” (38.28 mm)