Polaris Sportsman 500 Service Manual

BRAKES
9.1
SPECIFICATIONS
Front Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .275″ /7.0mm .150″ / 3.81mm
Brake Disc Thickness .150-.164″ / 3.810-4.166mm .140″ / 3.556mm
Brake Disc Thickness Variance Between
Measurements
- .002″ / .051mm
Brake Disc Runout - .005″ / .127mm
Rear Axle Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .275″ /7.0mm .150″ / 3.81mm
Brake Disc Thickness .177-.187″ /4.496-4.750mm .167″ / 4.242mm
Brake Disc Thickness Variance Between
Measurements
- .002″ / .051mm
Brake Disc Runout - .005″ / .127mm
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 Caliper Mounting Bolts 18.0 25
Output Shaft Caliper Mounting Bolts 15.0 21
Master Cylinder Mounting Bolts *55 in. lbs. 6.0
Master Cylinder Reservoir
Cover Bolt
*5 in. lbs. .6
Brake Line Banjo Bolt 15.0 21
Front Brake Disc 18.0 25
Front Wheel Mounting Nuts 20.0 28

Polaris Sportsman 500 Specifications

General

Brand	Polaris
Model	Sportsman 500
Category	Offroad Vehicle
Language	English