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9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 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 (P).
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 wear 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)
Front
Disc
Rear
Disc