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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
2. Inspect piston for nicks, scratches, pitting or wear.
Measure piston diameter and replace if damaged or
worn beyond service limit.
RZR / RZR S: Front Caliper Piston O.D.:
Standard: 1.002” (25.45 mm)
Service Limit: 1.000” (25.4 mm)
RZR 4: Front Caliper Piston O.D.:
Standard: 1.370” (34.80 mm)
Service Limit: 1.368” (34.75 mm)
3. Inspect the brake disc and pads as outlined in this
chapter.
Caliper Assembly
1. Install new O-rings in the caliper body. Be sure the
grooves are clean and free of residue or brakes may
drag upon assembly.
2. Coat pistons with clean Polaris DOT 4 Brake Fluid.
Install pistons with a twisting motion while pushing
inward. Piston should slide in and out of bore
smoothly, with light resistance.
3. Lubricate the mounting bracket pins with silicone
grease and install the rubber dust seal boots.
4. Compress the mounting bracket and make sure the
dust seal boots are fully seated. Install the brake
pads. Clean the disc and pads with brake parts
cleaner or denatured alcohol to remove any dirt, oil
or grease.
BRAKES
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