2011-2012 RANGER 800 XP / HD / CREW / 6x6 Chapter 9

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2011-2012 RANGER 800 XP / HD / CREW / 6x6 Chapter 9 | Manualzz

BRAKES

CHAPTER 9

BRAKES

GENERAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

TORQUE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2

BRAKE SYSTEM SERVICE NOTES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

BRAKE NOISE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3

HYDRAULIC BRAKE SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4

BRAKE SYSTEM EXPLODED VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5

MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

FOOT BRAKE PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6

BRAKE BLEEDING / FLUID CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.7

PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

EXPLODED VIEW (XP / HD / CREW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8

EXPLODED VIEW (6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9

INSPECTION / CABLE TENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.10

PARKING BRAKE CALIPER SERVICE (4X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.12

CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.13

NEW BRAKE PAD INSTALLATION / CALIPER INSTALLATION . . . . . . . . . . . . . . . . . 9.14

PARKING BRAKE CALIPER SERVICE (6X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15

CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.15

CALIPER DISASSEMBLY / INSPECTION / NEW BRAKE PAD INSTALLATION . . . . . 9.16

CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

PARKING BRAKE DISC SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17

FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18

PAD ASSEMBLY / INSTALLATION / BRAKE BURNISHING PROCEDURE. . . . . . . . . 9.19

FRONT CALIPER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20

CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21

CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22

CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23

FRONT BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.24

REAR BRAKE PADS (XP / HD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25

PAD INSPECTION / INSTALLATION / BRAKE BURNISHING PROCEDURE . . . . . . . 9.26

REAR BRAKE PADS (CREW / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27

PAD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27

PAD ASSEMBLY / INSTALLATION / BRAKE BURNISHING PROCEDURE. . . . . . . . . 9.28

REAR CALIPER SERVICE (XP / HD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29

CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29

CALIPER DISASSEMBLY / INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30

CALIPER ASSEMBLY / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.31

REAR CALIPER SERVICE (CREW / 6X6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32

CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.32

CALIPER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33

CALIPER INSPECTION / ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.34

CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35

REAR BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36

TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.37

9

9.1

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

GENERAL SPECIFICATIONS

Item

Front Brake Pad Thickness

Front Brake Disc Thickness

Front Brake Disc Runout

Item

Rear Brake Pad Thickness

Rear Brake Disc Thickness

Rear Brake Disc Runout

FRONT BRAKE SYSTEM

Standard

.298 ± .007" / 7.56 ± .178 mm

.188" ( 4.78 mm)

-

REAR BRAKE SYSTEM

Standard

.298 ± .007"/ 7.56 ± .178 mm

.188" (4.78 mm)

-

Service Limit

.180" (4.6 mm)

.170" (4.32 mm)

.010" (.254 mm)

Service Limit

.180" (4.6 mm)

.170" (4.32 mm)

.010" (.254 mm)

Item

Park Brake Pad Thickness

Park Brake Disc Thickness

TORQUE SPECIFICATIONS

PARK BRAKE SYSTEM

Standard

Inboard - .304” (7.72 mm)

Outboard - .360” (9.14 mm)

0.164” - 0.173” (4.17 - 4.39 mm)

SPECIAL TOOLS

Service Limit

.240" (6.1 mm)

.310” (7.87 mm)

.150" (3.81 mm)

Item

Front Caliper Mounting Bolts

Rear Caliper Mounting Bolts

Park Brake Assembly Bolts

Park Brake Caliper to Mount

Bracket Bolts

Park Brake Mount Bracket to

Transmission Bolts (4x4)

Park Brake Mount Bracket to

Rear Gearcase Bolts (6x6)

Park Brake Lever Mount Bolts

Brake Line Flare Fittings

Brake Line Banjo Bolts (All)

Front Brake Disc to Hub Bolts

Rear Brake Disc to Hub Bolts

Park Brake Disc Mounting Bolt

Brake Switch

Master Cylinder Mount Bolts

9.2

Torque ft. lbs.

30

30

35

18

40

18

13

12-15

15

18

28

10-15

12-15

15

54

24

18

16-20

20

24

38

14-20

16-20

20

Torque

Nm

41

41

47

24

Part Number

2870975

Tool Description

Mity Vac™ Pressure Test Tool

SPX Corp: 1-800-328-6657 or http://polaris.spx.com/

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

BRAKE SYSTEM SERVICE NOTES

Disc brake systems are light weight, low maintenance, and perform well in the conditions this vehicle will routinely encounter. There are a few things to remember when replacing disc brake pads or performing brake system service to ensure proper system function and maximum pad service life.

• Optional pads are available to suit conditions in your area. Select a pad to fit riding style and environment.

• DO NOT over-fill the master cylinder fluid reservoir.

• Make sure the brake pedal returns freely and completely.

• Adjust stop pin on front caliper after pad service.

• Check and adjust master cylinder reservoir fluid level after pad service.

• Make sure atmospheric vent on reservoir is unobstructed.

• Test for brake drag after any brake system service and investigate cause if brake drag is evident.

• Make sure caliper moves freely on guide pins (where applicable).

• Inspect caliper piston seals for foreign material that could prevent caliper pistons from returning freely.

• Perform a brake burnishing procedure after installing new pads to maximize service life.

• DO NOT lubricate or clean the brake components with aerosol or petroleum products. Use only approved brake cleaning products.

BRAKE NOISE TROUBLESHOOTING

Dirt or dust buildup on the brake pads and disc is the most common cause of brake noise (squeal caused by vibration).

If cleaning does not reduce the occurrence of brake noise, Permatex™ Disc Brake Quiet can be applied to the back of the pads. Follow directions on the package. This will keep pads in contact with caliper piston(s) to reduce the chance of squeaks caused by dirt or dust.

Possible Cause

Caliper piston(s) not returning

Operator error (riding the brake)

Loose wheel hub or bearings

Brake disc warped or excessively worn

Brake disc misaligned or loose

Wrong pad for conditions

Brake Noise Troubleshooting

Dirt, dust, or imbedded material on pads or disc

Pad(s) dragging on disc (noise or premature pad wear) because of improper adjustment

Master cylinder reservoir overfilled

Master cylinder compensating port restricted

Master cylinder piston not returning completely

Noise is from other source (axle, hub, disc or wheel)

Remedy

Spray disc and pads with CRC Brakeleen™ or an equivalent non-flammable aerosol brake cleaner. Remove pads and/or disc hub to clean imbedded material from disc or pads.

Adjust pad stop (front calipers)

Set to proper level

Clean compensating port

Inspect. Repair as necessary

Clean piston(s) seal

Educate operator

Check wheel and hub for abnormal movement.

Replace disc

Inspect and repair as necessary

If noise does not change when brake is applied check other sources. Inspect and repair as necessary

Change to a softer or harder pad

9

9.3

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

HYDRAULIC BRAKE SYSTEM OPERATION

The Polaris brake system consists of the following components or assemblies: brake pedal, master cylinder, hydraulic brake lines, brake calipers, brake pads, and brake discs, which are secured to the drive line.

When the foot activated brake lever is applied it applies pressure on the piston within the master cylinder. As the master cylinder piston moves inward it closes a small opening (compensating port) within the cylinder and starts to build pressure within the brake system. As the pressure within the system is increased, the pistons located in the brake calipers move outward and apply pressure to the moveable brake pads. These pads contact the brake discs and move the calipers in their floating bracket, pulling the stationary side pads into the brake discs. The resulting friction reduces brake disc and vehicle speed.

The friction applied to the brake pads will cause the pads to wear. As these pads wear, the piston within the caliper moves further outward and becomes self adjusting. Fluid from the reservoir fills the additional area created when the caliper piston moves outward.

Brake fluid level is critical to proper system operation. Too little fluid will allow air to enter the system and cause the brakes to feel spongy. Too much fluid could cause brakes to drag due to fluid expansion.

Located within the master cylinder is the compensating port which is opened and closed by the master cylinder piston assembly. As the temperature within the hydraulic system changes, this port compensates for fluid expansion or contraction. Due to the high temperatures created within the system during heavy braking, it is very important that the master cylinder reservoir have adequate space to allow for fluid expansion. Never overfill the reservoir! Do not fill the

reservoir beyond the MAX LEVEL line!

When servicing Polaris brake systems use only Polaris DOT 4 Brake Fluid (PN 2872189). WARNING: Once a bottle is opened, use what is necessary and discard the rest in accordance with local laws. Do not store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture. This causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of serious injury.

9.4

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

BRAKE SYSTEM EXPLODED VIEW

XP / HD Brake System

1

LH Rear Line

2

3

Cross Fitting

Master Cylinder

Top View

LH Front

Brake Line

LH Rear Caliper

2 1

3

MC Rear

Brake Line

1

Brake

Switch

RH Front

Brake Line

2

LH Front Caliper

RH Front Caliper

2

1

RH Rear Caliper

RH Rear Line

Master Cylinder

Side View

1

CREW / 6x6 Brake System

1

LH Rear Line

2

3

Cross Fitting

Master Cylinder

Top View

LH Front

Brake Line

2

LH Rear Caliper

1

3

MC Rear

Brake Line

1

Brake

Switch

RH Front

Brake Line

1

1

2

3

Caliper Banjo Style Fittings:

15 ft. lbs. (20 Nm).

All Caliper Bleed Screws:

47 in. lbs. (5.3 Nm)

All Flare Style Fittings:

12-15 ft. lbs. (16-20 Nm)

2

LH Front Caliper

RH Front Caliper

2

1

9

RH Rear Caliper

RH Rear Line Master Cylinder

Side View

1

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

1

1

2

3

Caliper Banjo Style Fittings:

15 ft. lbs. (20 Nm).

All Caliper Bleed Screws:

47 in. lbs. (5.3 Nm)

All Flare Style Fittings:

12-15 ft. lbs. (16-20 Nm)

9.5

BRAKES

MASTER CYLINDER

Removal

1.

Remove retaining clip (A) from the clevis pin (B) that attaches the master cylinder to the brake pedal lever.

Installation

1.

Reverse Steps 1-5 for master cylinder installation.

Refer to the torque specifications in the illustration.

2.

Remove LH wheel well panel to access master cylinder.

FOOT BRAKE PEDAL

C

Pedal Removal

1.

Remove the E-clip from the end of the brake pedal mount bracket.

B

Master

Cylinder

Brake Pedal

Mount Bracket

Clevis Pin

15 ft. lbs.

(20 Nm)

A

Clip

Bushing

E-Clip

Bushing

Brake Pedal

15 ft. lbs.

(20 Nm)

D

3.

Remove the two mounting bolts (C) that secure the master cylinder to the frame.

2.

Remove the retaining clip and clevis pin from the master cylinder to free it from the brake pedal.

4.

Remove master cylinder and place a fluid catch container under the master cylinder brake line banjo bolts (D).

3.

Slide the brake pedal and bushings off the mount bracket.

CAUTION

Pedal Installation

1.

Reverse Steps 1-3 for foot brake installation.

2.

Use a new E-clip upon installation.

Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact with finished surfaces.

5.

Loosen the brake line banjo bolts (D) and allow the fluid to drain.

NOTE: Make note of front and rear brake line orientation on the master cylinder.

6.

Dispose of brake fluid properly and do not re-use.

9.6

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

BRAKE BLEEDING / FLUID CHANGE

NOTE: When bleeding the brakes or replacing the fluid always start with the furthest caliper from the master cylinder. This procedure should be used to change fluid or bleed brakes during regular maintenance.

7.

Attach a tight-fitting, clear hose to the bleeder fitting.

Bleeder

Screw

CAUTION

Always wear safety glasses.

CAUTION

Brake fluid will damage finished surfaces.

Do not allow brake fluid to come in contact with finished surfaces.

1.

Locate master cylinder reservoir in the front LH wheel well area (Figure 1-6). Clean reservoir cover thoroughly.

2.

Remove cover from reservoir.

3.

If changing fluid, remove old fluid from reservoir with a Mity Vac™ pump or similar tool.

8.

Place a small amount of fresh brake fluid into a small, clear container and place the other end of bleeder hose into the container.

9.

Have an assistant slowly pump the brake pedal until pressure builds and then hold.

10. Quickly open and close the bleed screw while holding pressure on the brake pedal.

4.

Mity Vac™ (PN 2870975)

Add brake fluid to the indicated MAX level of reservoir

(Figure 1-6).

NOTE: Do not release brake pedal before bleeder screw is tight or air may be drawn into master cylinder.

11. Release brake pedal pressure. Check level of fluid in reservoir and add if necessary (Figure 1-6).

12. Repeat Steps 9, 10, and 11 until brake pedal is firm and no air can be seen moving through the clear hose.

Add fluid as necessary to maintain level in reservoir.

Add Fluid

HERE

Master Cylinder Fluid Level:

Between the MIN and MAX line.

Figure 1-6

Level Indicator

Polaris DOT 4 Brake Fluid

(P/N 2872189)

5.

Begin bleeding procedure with caliper furthest from master cylinder.

6.

Install a box-end wrench on caliper bleeder screw.

CAUTION

Maintain at least 1/2"(1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder.

13. Tighten bleeder screw and remove bleeder hose.

Torque bleeder screw to 47 in. lbs. (5.3 Nm).

14. Repeat Steps 9 - 13 for the remaining brake calipers.

15. Install master cylinder reservoir cover.

16. Field test machine at low speed before putting into service. Check for proper braking action and pedal reserve. With pedal firmly applied, pedal reserve should be no less than 1/2"(1.3 cm).

17. Check brake system for fluid leaks.

9

9.7

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

PARKING BRAKE

Exploded View (XP / HD / CREW)

Parking Brake

Lever

Cable

Clevis

Pin

Bolts

Clip

Tie Strap

Nuts

13 ft. lbs.

(18 Nm)

Clevis

Pin

14 ft. lbs.

(19 Nm)

Clip

Parking Brake

Caliper

Nuts

18 ft. lbs.

(24 Nm)

Mount Bracket

Transmission

Parking Brake Disc

Bolt

40 ft. lbs.

(54 Nm)

Bolts

40 ft. lbs.

(54 Nm)

9.8

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

Exploded View (6x6)

Parking Brake

Lever

Bolts

Clevis

Pin

Clip

Washer

Nuts

13 ft. lbs.

(18 Nm)

Screw

Cable

14 ft. lbs.

(19 Nm)

Clip

Bolt

Clevis

Pin

Parking Brake

Caliper

Nut

18 ft. lbs.

(24 Nm)

Mount Bracket

Nut

18 ft. lbs.

(24 Nm)

Rear Propshaft w/Parking Brake Disc

Bolts

9

Rear Gearcase

9.9

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

Inspection

1.

Inspect the parking brake cable and brake pads on the caliper assembly. Refer to the appropriate

“Parking Brake Caliper Service” procedure for brake pad replacement information.

1.

Pull back on the parking brake lever (located in the dash).

2.

After 3 clicks the “(P)” brake light should illuminate on the instrument cluster and the wheels of the vehicle should not rotate when turning by hand. After 8 full clicks of lever travel, the vehicle should not roll while parked.

Inboard Pad

Outboard Pad

3.

If the vehicle moves, adjustment is necessary.

4.

Adjust the parking brake cable where the cable attaches to the caliper mount bracket. The mount bracket is located on the left-hand side of the transmission behind the outer PVT cover (4x4) or on the rear gearcase (6x6).

Transmission

Outboard Pad

Inboard Pad

4x4

Adjustment Procedure

1.

Place the vehicle in neutral on a flat level surface.

2.

Carefully lift the rear of the vehicle off the ground and stabilize on jack stands.

3.

Locate the parking brake cable adjustment area where the cable attaches to the caliper mount bracket.

4x4

Propshaft

6x6

Cable Tension Adjustment

When the parking brake is fully engaged and the parking brake indicator is illuminated, engine speed is limited to

1300 RPM in all gears, including neutral. If throttle is applied, this limiting feature prevents operation, which protects the parking brake pads from excessive wear.

NOTE: Inspect the parking brake cable tension after the first 25 hours of operation and every 100 hours of operation afterwards to ensure proper cable tension.

Parking Brake

Cable Adjustment

Loss of tension in the parking brake cable will cause illumination of the parking brake light and activation of the limiting feature. If this occurs, inspect and adjust parking brake cable tension. If performing this service is difficult due to conditions or location, open the hood and temporarily disconnect the parking brake connector.

Reconnect parking brake connector as soon as it is practical and adjust parking brake cable to proper tension.

9.10

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

6x6

Parking Brake

Cable Adjustment

BRAKES

4.

Use two open-end wrenches and loosen the outer jam nut (D). Back out the outer jam nut (D) 1 1/2 turns.

Mount Bracket

To Parking

Brake Caliper

C D

4x4

C D

To Parking

Brake Caliper

6x6

Mount Bracket

5.

Now hold the outer jam nut (D) and turn in the inner jam nut (C) clockwise, until the jam nut is tight against the bracket.

6.

Repeat Step 4 and Step 5 until the proper adjustment is obtained for the parking brake.

NOTE: See Chapter 10 for more information on the parking brake switch.

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

9.11

9

BRAKES

PARKING BRAKE CALIPER SERVICE (4X4)

Exploded View

18 ft. lbs.

(24 Nm)

Hex Head

Mount Bolt

Pad & Holder

Thrust Washer

Stationary Actuator

Lever

Nut

Hex Nut

Sleeve

Plain

Washer

Asm. Bolt

35 ft. lbs.

(47 Nm)

Spring

Spring Pin

Shim Pack

(5 Shims)

Steel Balls (3) Nut

Figure 9.12

Caliper Removal

NOTE: Do not get oil, grease, or fluid on the parking brake pads. Damage to or contamination of the pads may cause the pads to function improperly.

1.

Remove the clip and pin (A) from the parking brake cable.

2.

Disconnect the rear differential solenoid harness.

Disconnect

A

NOTE: Be sure the parking brake is not engaged.

9.12

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

3.

Loosen the (2) bolts that retain the caliper to the mount bracket.

Caliper Disassembly / Inspection

NOTE: Refer to the “Electronic Parts Catalog” for parking brake caliper replacement information.

1.

Remove the two caliper assembly bolts (C).

C

4.

Remove the (3) fasteners retaining the parking brake mount bracket and remove the parking brake caliper as an assembly. NOTE: The image shown below

has the PVT system removed for picture clarity.

Mount

Bracket

5.

Lift the parking brake caliper and mount bracket off the brake disc. Remove the (2) caliper mounting bolts and remove the caliper from the mount bracket.

2.

Slide the brake pads and springs from the assembly.

NOTE: Retain the lever and ball bearings for reassembly.

3.

Inspect brake pads for excessive wear. Replace as needed.

4.

Check the three steel balls for any signs of cracking.

Replace as needed.

5.

Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed.

6.

Measure the thickness of the rear caliper parking brake pads. Replace assembly or pads as needed.

See illustration below for proper readings.

Inboard

Pad

Inboard Pad

New .304” (7.72 mm)

Limit: 0.24” (6.1 mm)

Outboard

Pad

9

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Outboard Pad

New 0.360” (9.14 mm)

Limit: 0.31” (7.87 mm)

Installed Disc to Park Brake

0.375” (0.953 cm)

New Rotor Disc Thickness

0.164” - 0.173”

(4.17 - 4.39 mm)

4x4

9.13

BRAKES

New Brake Pad Installation

NOTE: Parking Brake Pads can be replaced by ordering one of the following kits:

PN 2203148 - Brake Pad and Shim Kit

PN 2203147 - Brake Pad Kit

There may be more parts in the service kit than your brake requires. Check the parts list included with the kit for the exact quantities.

Caliper Installation

1.

Attach the parking brake caliper to the mount bracket and finger tighten the (2) mounting bolts.

1.

Using the stationary actuator, assemble the caliper components as shown below. Do not install the springs or shims yet. Measure the gap for the brake disc. Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to .203” - .193” (5.16 - 4.90 mm). For shim location, see Figure 9.12 on page 12.

Add shims until gap measures .203”-.193”

(5.16-4.90 mm)

2.

Place the parking brake assembly into place. Install and tighten the (3) mount bracket fasteners to specification.

= T

Parking Brake Caliper - Mount Bracket Bolts:

40 ft. lbs. (54 Nm)

3.

Tighten the (2) parking brake caliper mounting bolts to specification.

2.

Once you have determined the correct amount of shims to use, install the assembly bolts through the sleeves. Install the nuts and the correct amount of shims, the inner brake pad, springs, and outer brake pad. Torque the assembly nuts to 35 ft. lbs. (47 Nm).

18 ft. lbs.

(24 Nm)

= T

Parking Brake Caliper - Assembly Bolts:

35 ft. lbs. (47 Nm)

3.

Ensure the parking brake assembly functions properly by actuating the lever before reinstallation.

= T

Parking Brake Caliper - Mounting Bolts:

18 ft. lbs. (24 Nm)

4.

Connect the rear differential solenoid harness.

5.

Install the cable, pin and clip. Test the park brake for proper function.

9.14

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PARKING BRAKE CALIPER SERVICE (6X6)

Exploded View

Pad & Holder

Pad & Holder

18 ft. lbs.

(24 Nm)

Hex Head

Mount Bolt

Sleeve

Thrust Washer

BRAKES

Plain Washer

Hex Nut

Nut

Compression Spring

Shim Pack

(4 Shims)

Lever

Spring Pin

Asm. Bolt

35 ft. lbs.

(47 Nm)

Stationary Actuator

Steel Balls (3)

Figure 9.15

Caliper Removal

NOTE: Do not get oil, grease, or fluid on the parking brake pads. Damage to or contamination of the pads may cause the pads to function improperly.

1.

Remove the clip and pin (A) from the parking brake cable.

2.

If replacing the brake pads, slightly loosen the caliper assembly bolts before removing the complete caliper assembly. This will ease the caliper disassembly procedure later.

9

A

NOTE: Be sure the parking brake is not engaged.

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9.15

BRAKES

3.

Loosen the two brake caliper mounting bolts (B) in equal increments.

B

6.

Measure the thickness of the rear caliper parking brake pads. Replace assembly or pads as needed.

See illustration below for proper readings.

Inboard Pad

New .304” (7.72 mm)

Limit: 0.24” (6.1 mm)

Inboard

Pad

Outboard

Pad

Outboard Pad

New 0.360” (9.14 mm)

Limit: 0.31” (7.87 mm)

4.

Remove mounting bolts from mount bracket and lift the parking brake caliper assembly out of the vehicle.

Installed Disc to Park Brake

0.375” (0.953 cm)

Caliper Disassembly / Inspection

NOTE: Refer to the “Electronic Parts Catalog” for parking brake caliper replacement information.

New Rotor Disc Thickness

0.164” - 0.173”

(4.17 - 4.39 mm)

6x6

1.

Remove the two caliper assembly nuts (C) that were previously loosened during Step 2 of “Caliper

Removal”.

New Brake Pad Installation

C

NOTE: Parking Brake Pads can be replaced by ordering one of the following kits:

PN 2203148 - Brake Pad and Shim Kit

PN 2203147 - Brake Pad Kit

There may be more parts in the service kit than your brake requires. Check the parts list included with the kit for the exact quantities.

2.

Slide the brake pads and springs from the assembly.

NOTE: Retain the lever and ball bearings for reassembly.

1.

Using the stationary actuator, assemble the caliper components as shown below. Do not install the springs or shims yet. Measure the gap for the brake disc. Disassemble and add shims between thrust washer and the inside brake pad as needed to close the gap to .203” - .193” (5.16 - 4.90 mm). For shim location, see Figure 9.15 on page 15.

Add shims until gap measures .203” - .193”

(5.16 - 4.90 mm)

3.

Inspect brake pads for excessive wear. Replace as needed.

4.

Check the three steel balls for any signs of cracking.

Replace as needed.

5.

Check ball seats in lever and stationary actuator. If excessively worn, replace parts as needed.

9.16

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BRAKES

2.

Once you have determined the correct amount of shims to use, install the assembly bolts through the sleeves. Install the nuts and the correct amount of shims, the inner brake pad, springs, and outer brake pad. Torque the assembly nuts to 35 ft. lbs. (47 Nm).

= T

Parking Brake Caliper - Assembly Bolts:

35 ft. lbs. (47 Nm)

PARKING BRAKE DISC SERVICE

Disc Inspection / Removal (4x4)

1.

Measure brake disc with a micrometer. If thickness of disc is less than specified, replace the disc assembly.

2.

Remove the outer PVT cover, belt, drive clutch, driven clutch and inner PVT cover (see Chapter 6).

3.

Using a 1/2” socket and ratchet, remove brake disc retaining bolt and remove disc from the transmission.

3.

Ensure the parking brake assembly functions properly by actuating the lever before reinstallation.

New Disc:

0.164” - 0.173”

(4.17 - 4.39 mm)

Service Limit:

.150” (3.81 mm)

Apply

Loctite

TM

262

Remove

Bolt

Caliper Installation

1.

Install the parking brake assembly into place. Tighten the two mounting bolts in increments.

18 ft. lbs.

(24 Nm)

4.

Reverse this procedure to reinstall brake disc. Torque the disc mounting bolt to 10-15 ft. lbs. (14-20 Nm).

Disc Inspection / Removal (6x6)

1.

Measure the brake disc with a micrometer. If the thickness of the disc is less than specified, replace the rear propshaft assembly.

2.

Follow the rear prop shaft removal procedure listed in

Chapter 7 to remove the rear propshaft assembly.

9

New Disc: 0.164” - 0.173” (4.17 - 4.39 mm)

Disc Service Limit: 0.150” (3.81 mm)

Remove Bolts

2.

Torque the two mounting bolts to specification.

= T

Parking Brake Caliper - Mounting Bolts:

18 ft. lbs. (24 Nm)

3.

Install the cable, pin, and clip. Test the park brake for proper function.

3.

Refer to Chapter 7 to install rear propshaft assembly.

9.17

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BRAKES

FRONT BRAKE PADS

Pad Removal

1.

Elevate and support front of vehicle.

CAUTION

Use care when supporting vehicle so that it does not tip or fall.

Severe injury may occur if machine tips or falls.

2.

Remove the wheel nuts, washers and front wheel.

Loosen pad adjuster screw.

5.

Push the mounting bracket inward and slip outer brake pad out between the bracket and caliper body.

Pad

Adjuster

6.

Remove the inner pad from the bracket and caliper.

Pad Inspection

1.

Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

3.

Remove the upper and lower caliper mounting bolts and remove the caliper from the front hub.

NOTE: When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line.

4.

Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed.

Measure

Thickness

compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.

Remove excess fluid from reservoir as required.

9.18

Front Brake Pad Thickness

New: .298 ± .007” (7.56 ± .178 mm)

Service Limit: .180” (4.6 mm)

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BRAKES

Pad Assembly / Installation

1.

Lubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots.

5.

Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise).

1/2 Turn

Apply Grease to Each

Bracket Pin

Pad

Adjuster

2.

Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.

6.

Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

Master Cylinder Fluid

WARNING

Up to MAX line inside reservoir

If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads.

Use only new, clean pads.

7.

Install wheel and torque wheel nuts to specification.

= T

3.

Install caliper onto front hub and torque mounting bolts to specification.

Wheel Nuts:

Steel Wheels: 35 ft. lbs. (47 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

30 ft. lbs.

(41 Nm)

= T

Front Caliper Mounting Bolts:

30 ft. lbs. (41 Nm)

4.

Slowly pump brake pedal until pressure has been built up. Maintain at least 1/2, (12.7 mm) of brake fluid in reservoir to prevent air from entering brake system.

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).

9

9.19

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BRAKES

FRONT CALIPER SERVICE

Caliper Exploded View

Apply Polaris DOT 4 Brake

Fluid to Components

Apply Silicone Grease

C

B

47 in. lbs.

(5.3 Nm)

A

E

D

D

F

G

A. Socket Set Screw

B. Bleeder Screw

C. Caliper Assy.

D. Boots

E. Square O-rings

F. Pistons

G. Caliper Mount

H. Brake Pads

I. Brake Scraper

J. Bolts

H

Caliper Removal

1.

Elevate and safely support the front of the vehicle.

2.

Remove the (4) wheel nuts and the front wheel.

CAUTION

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur.

3.

Clean caliper area before removal.

4.

Place a container below the caliper to catch brake fluid when removing line. Remove brake line from caliper.

J

I

5.

Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed.

Pad

Adjuster

9.20

Remove

Brake Line

9923499 - 2011 / 2012 RANGER 800 Service Manual

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6.

Remove the two caliper mounting bolts and caliper.

BRAKES

IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used.

4.

Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O-rings should be replaced during caliper service.

Remove

Caliper Disassembly

1.

Remove both brake pads from the caliper (see

“FRONT BRAKE PADS - Pad Removal”).

2.

Remove the mount bracket assembly and dust boots from caliper. Thoroughly clean caliper before disassembly and prepare a clean work area.

5.

Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

3.

Use a commercially available caliper piston pliers to extract the pistons from the caliper.

Clean

Components

IMPORTANT: Be sure to clean the seal grooves in caliper body.

9

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9.21

BRAKES

Caliper Inspection Caliper Assembly

1.

Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.

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.

Seal

Grooves

New

O-Rings

= In. / mm.

Caliper Piston Bore I.D.:

Std: 1.373” (34.87 mm)

Service Limit: 1.375” (34.93 mm)

2.

Inspect piston for nicks, scratches, pitting or wear.

Measure piston diameter and replace if damaged or worn beyond service limit.

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.

Apply Grease to Each

Bracket Pin

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.

= In. / mm.

Caliper Piston O.D.:

Std: 1.370” (34.80 mm)

Service Limit: 1.368” (34.75 mm)

3.

Inspect brake disc and pads as outlined in this chapter.

9.22

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BRAKES

Caliper Installation

1.

Install caliper and torque mounting bolts to specification.

3.

Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn.

1/2 Turn

IMPORTANT: If brake disc scraper was removed, be sure to reinstall it upon caliper installation.

Disc

Scraper

Pad

Adjuster

30 ft. lbs.

(41 Nm)

4.

Perform brake bleeding procedure as outlined earlier in this chapter.

5.

Install wheel and torque wheel nuts to specification.

= T

= T

Front Caliper Mounting Bolts:

30 ft. lbs. (41 Nm)

Wheel Nuts:

Steel Wheels: 35 ft. lbs. (47 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

2.

Install brake line and torque the banjo bolt to the proper torque specification.

6.

Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.

Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

NOTE: If new brake pads are installed, brake burnishing is recommended (see “FRONT BRAKE

PADS - Brake Burnishing Procedure”).

9

15 ft. lbs.

(20 Nm)

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9.23

BRAKES

FRONT BRAKE DISC

Disc Runout

1.

Mount dial indicator as shown. Slowly rotate the disc and read total runout on the dial indicator. Replace disc if runout exceeds specification.

Brake Disc Thickness

New .188” (4.78 mm)

Service Limit .170” (4.32 mm)

Brake Disc Thickness Variance

Service Limit: .002” (.051 mm) difference between measurements

Disc Removal / Replacement

1.

Remove front brake caliper (see “Front Caliper

Service”).

2.

Remove cotter pin, castle nut and washers.

3.

Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub.

(4) Bolts

Brake Disc Runout:

Service Limit .010” (.254 mm)

Washers

Nut

Disc Inspection

Cotter Pin

1.

Visually inspect disc for scoring, scratches or gouges. Replace the disc if any deep scratches are evident.

4.

Clean the wheel hub mating surface and install new disc on wheel hub. Torque new bolts to 18 ft. lbs. (24

Nm).

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.

18 ft. lbs.

(24 Nm)

Measure

Thickness

Front

Disc

80 ft. lbs.

(108 Nm)

9.24

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BRAKES

REAR BRAKE PADS (XP / HD)

CAUTION

Pad Removal

Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.

1.

Elevate and support rear of machine.

CAUTION

5.

Install wheel hub assembly, washers, and castle nut.

Torque castle nut to 80 ft. lbs. (108 Nm) and install a new cotter pin.

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.

6.

Install front brake caliper (see “Front Caliper

Service”). Follow bleeding procedure outlined earlier in this chapter.

2.

Remove the rear wheel. Loosen pad adjuster screw

2-3 turns.

7.

Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.

Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

3.

Clean caliper area before removal.

4.

Remove caliper mounting bolts and lift caliper off of disc.

NOTE: When removing caliper, be careful not to damage brake line. Support caliper so as not to kink or bend brake line.

9

Remove Caliper Bolts

5.

Push caliper piston into caliper bore slowly with pads installed.

9.25

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BRAKES

Pad Installation compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.

Remove excess fluid from reservoir as required.

1.

Install new pads in caliper body.

6.

Remove the brake pads.

Pad Inspection

1.

Clean the caliper with brake cleaner or alcohol.

2.

Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

2.

Install caliper and torque mounting bolts.

30 ft. lbs.

(41 Nm)

9.26

Measure

Thickness

Rear Brake Pad Thickness

New .298 + .007” (7.56 + .178 mm)

Service Limit .180” (4.6 mm)

= T

Rear Brake Caliper Mounting Bolts:

30 ft. lbs. (41 Nm)

3.

Turn adjuster screw back in finger tight using a hex wrench.

4.

Slowly pump brake pedal until pressure has been built up. Maintain at least 1/2" (12.7 mm) of brake fluid in reservoir to prevent air from entering master cylinder.

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).

9923499 - 2011 / 2012 RANGER 800 Service Manual

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BRAKES

REAR BRAKE PADS (CREW / 6X6)

Pad Removal

1.

Elevate and support rear of vehicle.

CAUTION

Use care when supporting vehicle so that it does not tip or fall.

Severe injury may occur if machine tips or falls.

2.

Remove the wheel nuts, washers and rear wheel.

Loosen pad adjuster screw.

5.

Push the mounting bracket inward and slip outer brake pad out between the bracket and caliper body.

Pad

Adjuster

6.

Remove the inner pad from the bracket and caliper.

Pad Inspection

1.

Measure the thickness of the pad material. Replace pads if worn beyond the service limit.

3.

Remove the upper and lower caliper mounting bolts and remove the caliper from the front hub.

NOTE: When removing caliper, use care not to damage brake line. Support caliper to avoid kinking or bending brake line.

4.

Push caliper piston into caliper bore slowly using a

C-clamp or locking pliers with pads installed.

9

Measure

Thickness

compensating port into master cylinder fluid reservoir when piston is pushed back into caliper.

Remove excess fluid from reservoir as required.

Front Brake Pad Thickness

New: .298 ± .007” (7.56 ± .178 mm)

Service Limit: .180” (4.6 mm)

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9.27

BRAKES

Pad Assembly / Installation

1.

Lubricate mounting bracket pins with a light film of silicone grease and install rubber dust boots.

Apply Grease to Each

Bracket Pin

4.

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.

5.

Install the pad adjuster set screw and turn clockwise until stationary pad contacts disc, then back off 1/2 turn (counterclockwise).

1/2 Turn

Pad

Adjuster

2.

Compress mounting bracket and make sure dust boots are fully seated. Install pads with friction material facing each other.

WARNING

6.

Verify fluid level in reservoir is up to MAX line inside reservoir and install reservoir cap.

If brake pads are contaminated with grease, oil, or liquid soaked do not use the pads.

Use only new, clean pads.

Master Cylinder Fluid:

Up to MAX line inside reservoir

3.

Install caliper onto rear hub and torque mounting bolts to specification.

7.

Install wheel and torque wheel nuts to specification.

30 ft. lbs.

(41 Nm)

= T

Wheel Nuts:

Steel Wheels: 35 ft. lbs. (47 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

= T

Rear Caliper Mount Bolt Torque:

30 ft. lbs. (41 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).

9.28

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BRAKES

REAR CALIPER SERVICE (XP / HD)

Rear Caliper Exploded View

Apply Polaris DOT 4 Brake

Fluid to Component

Apply Silicone Grease

D

A

E

F

G

H

A. Socket Set Screw

B. Bleeder Screw

C. Caliper Assy.

D. Boot

E. Square O-rings

F. Piston

G. Caliper Mount

H. Brake Pads

B

47 in. lbs.

(5.3 Nm)

C

E

Caliper Removal

1.

Safely support the rear of the machine.

CAUTION

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur if machine tips or falls.

2.

Place a container to catch brake fluid draining from brake lines. Use a wrench to remove the brake line.

3.

After the fluid has drained into the container, remove the two caliper mounting bolts and remove caliper.

9

4.

Clean disc, caliper body, and pistons with brake cleaner or alcohol.

9.29

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BRAKES

Caliper Disassembly

1.

Remove brake pad adjuster screw (A).

2.

Push upper pad retainer pin inward and slip brake pads past edge, if pads are still installed.

3.

Remove mounting bracket (B) and dust boot (C).

B

Pads

C

F

D

Caliper Inspection

1.

Inspect caliper body for nicks, scratches or wear.

Measure bore size and compare to specifications.

Replace if damage is evident or if worn beyond service limit.

E

A

4.

Remove piston (D) and square O-rings (E) from the caliper body (F).

= In. / mm.

Caliper Piston Bore I.D.:

Std: 1.505” (38.23 mm)

Service Limit: 1.507” (38.28 mm)

2.

Inspect piston for nicks, scratches, wear or damage.

Measure diameter and replace if damaged or worn beyond service limit.

5.

Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

NOTE: Be sure to clean seal grooves in caliper body.

9.30

= In. / mm.

Caliper Piston O.D.:

Std: 1.500” (38.10 mm)

Service Limit: 1.498” (38.05 mm)

3.

Inspect the brake disc and pads as outlined for brake pad replacement in this chapter.

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BRAKES

Caliper Assembly

1.

Install new square O-rings (A) in the caliper body. Be sure that the grooves are clean and free of residue or brakes may drag.

A

Caliper Installation

1.

Install the rear caliper onto the mounting bolts.

Torque mounting bolts to 30 ft. lbs. (41 Nm).

2.

Install brake line banjo bolt. Torque banjo bolt to 15

ft. lbs. (21 Nm).

30 ft. lbs.

(41 Nm)

B

15 ft. lbs.

(21 Nm)

2.

Coat the piston with clean DOT 4 Brake Fluid

(PN 2872189). Install piston (B) with a twisting motion while pushing inward. Piston should slide in and out of bore smoothly, with light resistance.

3.

Install the rear wheel and torque wheel nuts to specification. Carefully lower the vehicle.

3.

Lubricate the mounting bracket pins with silicone grease and install the rubber dust seal boots.

= T

Wheel Nuts:

Steel Wheels: 35 ft. lbs. (47 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

4.

Compress the mounting bracket and make sure the dust seals 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.

4.

Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.

Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

NOTE: If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE

PADS - Brake Burnishing Procedure”).

9

9.31

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BRAKES

REAR CALIPER SERVICE (CREW / 6X6)

Rear Caliper Exploded View

Apply Polaris DOT 4 Brake

Fluid to Component

Apply Silicone Grease

F

E

47 in. lbs.

B

(5.3 Nm)

A

C

G

H

I

A. Socket Set Screw

B. Bleeder Screw

C. Caliper Assy.

D. Boot

E. Square O-rings (large)

F. Square O-rings (small)

G. Piston

H. Caliper Mount

I. Brake Pads

Caliper Removal

1.

Elevate and safely support the rear of the vehicle.

CAUTION

Use care when supporting vehicle so that it does not tip or fall. Severe injury may occur.

2.

Remove (4) wheel nuts, (4) washers and rear wheel.

3.

Clean caliper area before removal.

4.

Place a container below the caliper to catch brake fluid. Remove brake line from caliper.

Pad

Adjuster

D

5.

Loosen brake pad adjustment set screw to allow brake pad removal after the caliper is removed.

9.32

Remove

Brake Line

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

6.

Remove the two caliper mounting bolts and caliper.

BRAKES

IMPORTANT: Do not remove the caliper pistons with a standard pliers. The piston sealing surfaces will become damaged if a standard pliers is used.

4.

Once the pistons are removed, use a pick to carefully remove the square O-rings from the caliper. O-rings should be replaced during caliper service.

Remove

Caliper Disassembly

1.

Remove both brake pads from the caliper. Refer to

“REAR BRAKE PADS (CREW / 6X6)”.

2.

Remove mount bracket assembly and dust boots from caliper. Thoroughly clean caliper before disassembly and prepare a clean work area for disassembly.

5.

Clean the caliper body, piston, and retaining bracket with brake cleaner or alcohol.

3.

Use a commercially available caliper piston pliers to extract the pistons from the caliper.

Clean

Components

IMPORTANT: Be sure to clean the seal grooves in caliper body.

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9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

9.33

BRAKES

Caliper Inspection Caliper Assembly

1.

Inspect caliper body for nicks, scratches, pitting or wear. Measure bore size and compare to specifications. Replace if damaged or worn beyond service limit.

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.

Seal

Grooves

New

O-Rings

= In. / mm.

Caliper Piston Bore I.D.:

Std: 1.192” (30.28 mm)

Service Limit: 1.194” (34.33 mm)

2.

Inspect piston for nicks, scratches, pitting or wear.

Measure piston diameter and replace if damaged or worn beyond service limit.

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.

Apply Grease to Each

Bracket Pin

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.

= In. / mm.

Caliper Piston O.D.:

Std: 1.186” (30.12 mm)

Service Limit: 1.184” (30.07 mm)

3.

Inspect the brake disc and pads as outlined in this chapter.

9.34

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© Copyright 2011 Polaris Sales Inc.

Caliper Installation

1.

Install caliper and torque bolts to specification.

BRAKES

4.

Perform brake bleeding procedure as outlined earlier in this chapter.

5.

Install wheel and torque wheel nuts to specification.

30 ft. lbs.

(41 Nm)

= T

Wheel Nuts:

Steel Wheels: 35 ft. lbs. (47 Nm)

Aluminum Wheels: 30 ft. lbs. + 90° (1/4 turn)

= T

Rear Caliper Mount Bolt Torque:

30 ft. lbs. (41 Nm)

2.

Install brake line and torque the banjo bolt to the proper torque specification.

6.

Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.

Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

NOTE: If new brake pads are installed, brake burnishing is recommended (see “REAR BRAKE

PADS - Brake Burnishing Procedure”).

15 ft. lbs.

(20 Nm)

3.

Install the pad adjustment screw and turn until stationary pad contacts disc, then back off 1/2 turn.

1/2 Turn

Pad

Adjuster

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© Copyright 2011 Polaris Sales Inc.

9.35

9

BRAKES

REAR BRAKE DISC

Disc Runout

1.

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 specification.

Brake Disc Thickness:

New .188” (4.78 mm)

Service Limit .170” (4.32 mm)

Brake Disc Thickness Variance:

Service Limit .002” (.051 mm) difference between measurements

Disc Removal / Replacement

1.

Remove rear brake caliper (see “Rear Caliper

Service”).

2.

Remove cotter pin, castle nut and washers.

3.

Remove the wheel hub assembly from the vehicle and remove the (4) bolts retaining the disc to the hub.

(4) Bolts

Brake Disc Runout

Service Limit .010” (.254 mm)

Washers

Nut

Disc Inspection

Cotter

Pin

1.

Visually inspect disc for scoring, scratches or gouges. Replace disc if any are evident.

4.

Clean the wheel hub mating surface and install new disc on wheel hub.

2.

Use a 0-1" micrometer and measure disc thickness at

8 different points around perimeter of disc. Replace disc if worn beyond service limit.

5.

Install new bolts and torque to 28 ft. lbs. (38 Nm).

28 ft. lbs.

(38 Nm)

9.36

Rear

Disc

Measure

Thickness

110 ft. lbs.

(150 Nm)

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

BRAKES

TROUBLESHOOTING

CAUTION

Always use new brake disc mounting bolts. The bolts have a pre-applied locking agent which is destroyed upon removal.

6.

Install wheel hub assembly, washers, and castle nut.

Torque castle nut to 110 ft. lbs. (150 Nm) and install a new cotter pin.

7.

Install rear brake caliper (see “REAR CALIPER

SERVICE”). Follow the bleeding procedure outlined earlier in this chapter.

8.

Field test unit for proper braking action before putting into service. Inspect for fluid leaks and firm brakes.

Make sure the brake is not dragging when pedal is released. If the brake drags, re-check assembly and installation.

Brakes Squeal / Poor Brake Performance

• Air in system

• Water in system (brake fluid contaminated)

• Caliper/disc misaligned

• Caliper dirty or damaged

• Brake line damaged or lining ruptured

• Worn disc and/or friction pads

• Incorrectly adjusted stationary pad

• Worn or damaged master cylinder or components

• Damaged break pad noise insulator

Pedal Vibration

• Disc damaged

• Disc worn (runout or thickness variance exceeds service limit)

Caliper Overheats (Brakes Drag)

• Compensating port plugged

• Pad clearance set incorrectly

• Parking brake lever incorrectly adjusted

• Brake pedal binding or unable to return fully

• Parking brake left on

• Residue build up under caliper seals

• Operator riding brakes

Brakes Lock

• Alignment of caliper to disc

• Caliper pistons sticking

• Improper assembly of brake system components

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© Copyright 2011 Polaris Sales Inc.

9.37

BRAKES

NOTES

9.38

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.

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