Polaris Outlaw 500, Service Manual, Page: 151 / 202

6.2
BRAKES
BRAKE SPECIFICATIONS
General Specifications
Torque Specifications
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures
are used when torquing certain bolts and fasteners.
Special Tools
FRONT BRAKE CALIPER
Item Standard Service Limit
Brake Pad Thickness .298
″
/ 7.6 mm .180
″
/ 4.6 mm
Brake Disc Thickness .158” / 4.013 mm .140
″
/ 3.556 mm
Brake Disc Thickness Variance
Between Measurements
– .002
″
/ .051 mm
Brake Disc Runout – .010
″
/ .254 mm
RH Handle Bar Master Cylinder I.D. – .551” / 14 mm
REAR BRAKE CALIPER
Item Standard Service Limit
Brake Pad Thickness .298
″
/ 7.6 mm .180
″
/ 4.6 mm
Brake Disc Thickness .158” / 4.013 mm .140
″
/ 3.556 mm
Brake Disc Thickness Variance
Between Measurements
– .002
″
/ .051 mm
Brake Disc Runout – .010
″
/ .254 mm
Master Cylinder I.D. – Aux. Rear .500” / 12.7 mm
ITEM
TORQUE
(ft. lbs. except where noted)
TORQUE
(Nm)
Front Caliper Mounting Bolts 18 24
Rear Caliper Mounting Bolts 18 24
Rear Master Cylinder Mounting Bolts 8 11
Front Master Cylinder Reservoir Cover Bolts 11 (in. lbs.) 1.24
Brake Line Banjo Bolts 15 20
Brake Disc Mounting Bolts 18 24
Wheel Mounting Nuts 25 34
Front Master Cylinder Clamp Bolts 85 (in. lbs.) 9.6
Rear Caliper Bleed Screws 27 (in. lbs.) 3.1
Front Caliper Bleed Screws 47 (in. lbs.) 5.3
Rear Caliper Slide Bolts 33 45
Rear Caliper Anvil Bolts 16-18 22-24
Rear Hub Nut 90 122
Upper A-arm Bolt 30 41
Part Number Tool Description
2870975 Mity Vac™
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