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MAINTENANCE
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
BRAKE SYSTEM
Brake Fluid Inspection
Always check the brake pedal travel and inspect the brake
fluid reservoir level before each operation. If the fluid level
is low, add DOT 4 brake fluid only.
Brake fluid should be changed every two years. The fluid
should also be changed anytime the fluid becomes
contaminated, the fluid level is below the minimum level,
or if the type and brand of the fluid in the reservoir is
unknown.
The brake fluid master cylinder reservoir can be accessed
through the left front wheel well.
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
3. View the brake fluid level in the reservoir. The level
should be between the MAX and MIN level lines.
4. If the fluid level is lower than the MIN level line, add
brake fluid until it reaches the MAX level line.
5. Install the reservoir cap and apply the brake pedal
forcefully for a few seconds and check for fluid
leakage around the master cylinder fittings and the
brake caliper fittings.
Brake Pad / Disc Inspection
1. Check the brake pads for wear, damage, or
looseness.
2. Inspect the brake pad surface for excessive wear.
3. Pads should be changed when the friction material is
worn to .040” (1 mm).
4. Check surface condition of the brake discs.
5. Measure the thickness of the front and rear brake
discs.
6. The disc(s) should be replaced if thickness is less than
.170” (4.32 mm).
Brake Hose and Fitting Inspection
Check brake system hoses and fittings for cracks,
deterioration, abrasion, and leaks. Tighten any loose
fittings and replace any worn or damaged parts.
Master Cylinder
Maximum
Minimum
Measure Pad Material
Service Limit:
.040" (1 mm)
Thickness
Measure Brake Disc Thickness
Service Limit:
.170" (4.32 mm)
Rear
Disc
Front
Disc
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