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BRAKE SYSTEM
CHAPTER 9
BRAKE SYSTEM
GENERAL INFORMATION............................................................................... 9.3
SPECIAL TOOLS ...................................................................................... 9.3
GENERAL SPECIFICATIONS.......................................................................... 9.3
BRAKE SYSTEM SERVICE NOTES ................................................................... 9.3
BRAKE NOISE TROUBLESHOOTING ................................................................. 9.4
HYDRAULIC BRAKE SYSTEM OPERATION........................................................... 9.4
BRAKE SYSTEM OVERVIEW ........................................................................... 9.6
BRAKE SYSTEM ASSEMBLY VIEW ................................................................... 9.6
BRAKE LINE ROUTING / RETENTION................................................................. 9.7
FRONT BRAKE LINES TO MASTER CYLINDER .................................................. 9.7
REAR BRAKE LINE - MASTER CYLINDER TO JUNCTION BLOCK ............................... 9.8
REAR BRAKE LINES - JUNCTION BLOCK TO CALIPERS ........................................ 9.9
MASTER CYLINDER....................................................................................9.10
MASTER CYLINDER REMOVAL......................................................................9.10
MASTER CYLINDER INSTALLATION .................................................................9.10
BRAKE BLEEDING / FLUID CHANGE ................................................................9.12
BRAKE PEDAL LEVER .................................................................................9.14
BRAKE PEDAL REMOVAL ...........................................................................9.14
BRAKE PEDAL INSTALLATION.......................................................................9.14
FRONT BRAKES ........................................................................................9.15
PAD REMOVAL.......................................................................................9.15
PAD INSPECTION....................................................................................9.15
PAD ASSEMBLY / INSTALLATION ....................................................................9.16
BRAKE BURNISHING PROCEDURE .................................................................9.16
FRONT CALIPER ASSEMBLY VIEW..................................................................9.17 9
CALIPER REMOVAL .................................................................................9.18
CALIPER DISASSEMBLY.............................................................................9.19
CALIPER INSPECTION...............................................................................9.20
CALIPER ASSEMBLY ................................................................................9.20
CALIPER INSTALLATION.............................................................................9.21
DISC RUNOUT .......................................................................................9.22
DISC INSPECTION...................................................................................9.22
DISC REPLACEMENT................................................................................9.23
REAR BRAKES..........................................................................................9.24
PAD REMOVAL.......................................................................................9.24
PAD INSPECTION....................................................................................9.25
PAD ASSEMBLY / INSTALLATION ....................................................................9.26
BRAKE BURNISHING PROCEDURE .................................................................9.26
REAR CALIPER ASSEMBLY VIEW ...................................................................9.27
CALIPER REMOVAL .................................................................................9.28
CALIPER DISASSEMBLY.............................................................................9.29
9928492 R06 - 2017-2018 RZR XP 1000 / XP4 1000 Service Manual 9.1
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