10.22
9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual
© Copyright Polaris Industries Inc.
FRONT BRAKE DISC REPLACEMENT
1. Dismount the wheel hub assembly from the vehicle
by pulling straight out.
2. Remove the tie-rod to gain access to the front caliper.
3. Remove the front caliper and brake disc.
4. Replace brake disc with a new one.
BRAKE CALIPER / PAD INSTALLATION
1. Install the bolt
q
retaining the brake line fitting to the
caliper. Torque banjo bolt to specification.
NOTICE
The calipers have self-orienting features, brake lines do
not need to be oriented if installed correctly.
TORQUE
Brake Line Banjo Bolt:
15 ft-lbs (20 Nm)
2. Install the inner pad on the bracket and caliper.
3. Install the outer brake pad between the bracket and
caliper body.
4. Install the caliper on the knuckle. Torque mounting
fasteners to specification.
TORQUE
Brake Caliper Mounting Bolts:
73 ft-lbs (100 Nm)
5. Slowly pump the brake pedal until pressure has been
built up. Maintain at least 1/2" (12.7 mm) of brake
fluid in the reservoir to prevent air from entering the
brake system.
6. Install the adjustment set screw and turn clockwise
until stationary pad contacts disc, then back off 1/2
turn (counterclockwise).
7. Install the front wheel and the wheel nuts.
TORQUE
Wheel Lug Nuts:
148 ft-lbs (200 Nm)
BRAKE BURNISHING PROCEDURE
It is required that a burnishing procedure be performed
after installation of new brake pads to extend service life
and reduce noise.
Start machine and slowly increase speed to 30 mph.
Gradually apply brakes to stop machine. Allow pads and
disc to cool sufficiently during the procedure. Do not
allow pads or disc to become hot or warping may result.
Repeat this procedure 10 times. Do not make more
than 3 stops per 1 mile (1.6 km).
BRAKE SYSTEM
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