Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 210 / 289

GENERAL INFORMATION
9.2
SPECIFICATIONS
Item Standard Service Limit
Brake Pad Thickness .298
±
.0073
″
/ 7.56
±
.185 mm .180
″
/ 4.6 mm
Brake Disc Thickness .150-.165
″
/ 3.810-4.191 mm .140
″
/ 3.556 mm
Brake Disc Thickness Variance Between
Measurements
- .002
″
/ .051 mm
Brake Disc Runout - .010
″
/ .254 mm
RH Master Cylinder I.D. .625
″
/ 15.8 mm Replace if spec not met
LH Master Cylinder I.D. .750
″
/ 18.4 mm Replace if spec not met
Rear Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .38
″
/ 9.65mm .170
″
/ 4.32mm
Brake Disc Thickness .178-.198
″
/ 4.52-5.03mm .168
″
/ 4.27mm
Brake Disc Thickness Variance Between
Measurements
- .002
″
/ .051mm
Brake Disc Runout - .010
″
/ .254mm
TORQUE SPECIFICATIONS
Item Torque
(ft. lbs. except where noted*)
Torque
(Nm)
Front Caliper Mounting Bolts 18.0 25
Rear Caliper Mounting Bolts 15.0 21
Master Cylinder Mounting Bolts *25 in. lbs. 3.0
Master Cylinder Reservoir
Cover Bolt
*5 in. lbs. 0.56
Brake Line Banjo Bolt 15.0 21
Front Brake Disc 18.0 25
Rear Brake Disc 24.0 33
Front Wheel Mounting Nuts 20.0 28
Bleeder Screw 2.5 3.4
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certian bolts and fasteners.