9
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
9.29
REAR 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.
MEASUREMENT
Brake Disc Thickness
New: 0.188″ (4.78 mm)
Service Limit: 0.170″ (4.32 mm)
MEASUREMENT
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.
MEASUREMENT
Brake Disc Runout:
Service Limit: 0.010″ (0.254 mm)
REAR DISC REPLACEMENT
1. Remove the rear brake caliper. (see Chapter 9 –
REAR CALIPER SERVICE, page
2. Remove wheel hub cotter pin
r
, castle nut
e
and
washers
w
.
3. Remove the hub assembly from the vehicle and
remove the four bolts
q
retaining the disc to the hub.
4. Clean the wheel hub mating surface and install new
disc on wheel hub.
5. Install new bolts
t
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.
TORQUE
Brake Disc Mounting Bolts:
18 ft-lb (24 Nm)
6. Install wheel hub assembly, washers, and castle nut.
Torque castle nut to specification and install a new
cotter pin.
BRAKE SYSTEM
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