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9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
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)
Disc Replacement
1. Remove rear brake caliper (see “REAR CALIPER
SERVICE”).
2. Remove wheel hub cotter pin (Item 4), castle nut
(Item 3) and washers (Item 2).
3. Remove the hub assembly from the vehicle and
remove the four bolts (Item 1) retaining the disc to
the hub.
4. Clean the wheel hub mating surface and install new
disc on wheel hub.
5. Install new bolts (Item 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)
BRAKES
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