How to Replace Polaris Ranger 900XP Rear Brake Pads

A Polaris side-by-side could weigh well over 1,400 pounds while loaded up with you, your passengers and all your gear, so it needs a lot of stopping power. 

This means you need to inspect the brake pads frequently and change them when they get too low. The rear brake pads on a Polaris Ranger need replacing once the thickness of the pad material is less than 4mm, or about 0.16 inches. Watch the video above and follow the steps below to change the rear brake pads on a Polaris Ranger 900XP.

Tools and Parts – Polaris Ranger 900 Rear Brake Pads Change

• Ratchet and extensions
• 15mm, 19mm sockets
• 5mm Allen
• C-clamp
• Torque wrench

• Brake/contact cleaner
• Red threadlocker
• Grease
• Rear brake pad kit
• Brake boot kit

Replacing Polaris 900XP Rancher Rear Brake Pads

Step 1. Support the Ranger on jack stands and remove the rear wheels.

NOTE: A Polaris Ranger 900XP weighs too much to trust a jack to support it alone. Always use jack stands when lifting and working on your UTV.

Step 2. Remove the 5mm brake pad adjustment screw located at the top rear of the caliper housing.

Step 3. Remove the 15mm brake caliper mounting bolts and slide the entire caliper assembly off the brake rotor.

Step 4. Use a C-clamp to push the brake cylinder back into the caliper housing. Put the C-clamp over the old brake pads and compress them down until they bottom out on the caliper mount.

Step 5. Remove the old pads from the caliper mount pins and discard them. 

NOTE: You’ll have to press the caliper mount onto the caliper housing to make room for the brake pads to slide off the mount pins.

Step 6. Check that the caliper housing slides freely on the caliper mount pins, and that the two rubber brake boots between the housing and mount are free from splits or damage. 

NOTE: If the boots are damaged or the caliper housing and mount don’t slide freely, follow Step 7. Otherwise, move on to Step 8.

Step 7. Slide the caliper housing from the caliper mount pins and remove the rubber brake boots. Clean everything with brake/contact cleaner, then grease the caliper mount pins and pack a pair of new brake boots with grease. Install the new boots into the caliper housing and slide the caliper mount back into the housing. 

NOTE: Make sure the new boots are correctly seated in the housing and on the mount so they’re making a good seal.

Step 8. Install new brake pads onto the caliper mount pins, and reinstall the complete caliper assembly back over the brake rotor. Torque the caliper mount bolts to 46 foot-pounds.

Step 9. Pump the brake pedal a couple of times to center the brake pads and the caliper assembly. Put a drop of red threadlocker on the brake pad adjustment screw and reinstall the screw into the caliper housing. Tighten the adjustment screw until it bottoms out, then back it off by half a turn.

Step 10. Reinstall the wheels, then torque the lug nuts to the correct specification for your exact model and you’re done. 

NOTE: For aluminum wheels, 120 foot-pounds and for steel wheels, 60 foot-pounds.

PRO TIP: Before you go back to punishing your side-by-side on the trails, you’ll need to bed those new brake pads in. The best way to bed in Ranger brake pads is to run up to a speed of about 30mph, then gently slow to a standstill only using the brakes. Repeat this a few times and your new pads will be nicely bedded in.

Ready to do the front brake pads next? Watch the video above to learn how to change the front brake pads on a Polaris Ranger 900XP.