Polaris 2005 Sportsman MV7, Service Manual

Page: 234 / 312

BRAKES
9.2
SPECIAL TOOLS
PART NUMBER TOOL DESCRIPTION
2870975 Mity Vac
t
Pressure Test Tool
SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .298
″
/ 7.6mm .180
″
/ 4.6mm
Brake Disc Thickness .150-.165
″
/ 3.81-4.19mm .140
″
/ 3.556mm
Brake Disc Thickness Variance Between
Measurements
- .002
″
/ .051mm
Brake Disc Runout - .010
″
/ .254mm
Rear Axle Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .318
″
/ 7.6mm .180
″
/ 4.6mm
Brake Disc Thickness .150-.165
″
/ 3.81-4.19mm .140
″
/ 3.56mm
Brake Disc Thickness Variance Between
Measurements
- .002
″
/ .051mm
Brake Disc Runout - .010
″
/ .254mm
Master Cylinder I.D. - Front .750
″
Master Cylinder I.D. - Aux. Rear .500
″
TORQUE SPECIFICATIONS
Item Torque
(ft. lbs. except where noted*)
Torque
(Nm)
Front/Rear Caliper Mounting Bolts 18.0 24
Handlebar Master Cylinder Clamp
Bolts
*25 in. lbs. 3.0
Hand Master Cylinder Reservoir
Cover Bolt
*5 in. lbs. 0.56
Brake Line Banjo Bolt 15.0 21
Front Brake Disc Bolts 18.0 24
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are
used when torquing certain bolts and fasteners.