Required Tools and Supplies:
- Shop Rags
- Brake Pad and Rotor Measurement Tools
- 19mm Socket
- Breaker Bar
- Tire Depth Gauge
- Tread Pressure Gauge
- Torque Wrench
To learn more about tools, read the Tools and Fasteners Guide.
Always wear safety glasses and nitrile gloves while servicing your Polaris RZR.
To perform a brake inspection and to inspect and rotate your tires on your RZR XP 1000 or XP 4 1000, follow these steps:
1. Take a close look at each tire.
- Verify there is sufficient tread depth. Tires should be replaced once they reach one-eighth inch or 3 millimeters of tread depth.
- Inspect for damage that may compromise the integrity of the tire.
- Next, inspect the tire pressure and verify it is set to specification. Tire pressure on RZR XP 1000 models should be 16 psi (110 kPa) for all tires. Tire pressure on RZR XP 4 1000 models should be 19 psi (131 kPa) for the front and 20 psi (138 kPa) for the rear. Tire pressure on RZR XP 1000 Trails & Rocks Edition models should be 12 psi (83 kPa) for the front and 16 psi (110 kPa) for the rear.
- Lastly, take a close look at how the tires are wearing. If there is irregular wear, it may be time for a rotation.
2. Remove the tires.
- Using a 19mm socket, loosen the lug nuts while the vehicle is on the ground but do not remove.
- Safely elevate the vehicle. Reference your Owner’s Manual for proper lifting techniques.
- Remove the lug nuts and set aside.
- Then remove the wheels and set aside.
3. Before rotating the tires, it's a great time to look at the brake system.
- Start by inspecting the fluid level and condition in the master cylinder. Ensure the level is between the min and max marks. Add fluid as necessary. DOT 4 Brake Fluid is part number 2872189. Caution: After opening a bottle of brake fluid, always discard any unused portion. Brake fluid rapidly absorbs moisture from the air, which causes the boiling temperature to drop. This can lead to early brake fade and the possibility of an accident or serious injury.
- Look at the banjo bolts on the inside of the master cylinder for leaks.
- Follow the lines all the way to both front calipers, looking for any leaks, kinks or damage. Also, ensure the brake line retainers are properly secured.
- Inspect the connections at the front brake calipers for leaks.
- Next follow the brake lines back to the rear of the vehicle, checking for leaks, kinks and damage.
- Inspect the connections at the junction block in the driver’s rear wheel well.
- Follow the brake line to the rear brake calipers, looking for leaks, kinks and damage. Also, ensure the brake line retainers are properly secured.
- Inspect the rear brake calipers and connections for leaks.
- If inspection reveals any concerns, DO NOT attempt to drive the vehicle. See your authorized Polaris Service Center.
4. Next, take a look at the brake pads and rotors. Caution: Brake rotors can become extremely hot after operation. Allow the rotors to cool completely before performing maintenance to prevent the risk of burns.
- Check the brake pad thickness using a suitable tool. Be sure to check the thickness on the inside pads as well. Replace any brake pads that are worn beyond their minimum thickness of 0.180 inches (4.6 mm) with the backing plate.
- Next, use a brake rotor measuring tool to measure the thickness of the brake rotors. Replace the rotors if they are worn below the minimum thickness of 0.170 inches (4.32 mm).
5. Once the brake system inspection has been completed, the tires can be rotated and reinstalled. Rotate the wheels as needed based on wheel configuration. Caution: Due to different configurations, some wheels may not be able to be rotated. Always pay attention to all markings and directional indicators on the tires.
- Install the wheels on the vehicle and hand tighten the lug nuts.
- Safely lower the vehicle until the tires begin to touch the ground. Reference your Owner’s Manual for proper lowering techniques.
- Torque the lug nuts to 120 ft-lbs (162.7 Nm) in a crisscross pattern.
- Lower the vehicle completely.
For more information, see your authorized Polaris Dealer. Find a dealer near you with the Dealer Locator.
Maintenance tips, procedures and specifications can be found in your Owner's Manual.
To find diagrams and replacement part numbers, use the online parts catalog.
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