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

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

9923499 - 2011 / 2012 RANGER 800 Service Manual

© Copyright 2011 Polaris Sales Inc.