9
9.3
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
SPECIFICATIONS
Special Tools
Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/
Torque Table
TORQUE SPECIFICATIONS
ITEM
TORQUE FT-LBS (IN-
LBS)
TORQUE NM
Front / Rear Caliper Mounting Bolts
18 24
Handlebar Master Cylinder Clamp Bolts (25 in-lbs)
3.0
Hand Master Cylinder Reservoir Cover Screws (7 in-lbs)
0.79
Brake Line Banjo Bolt
15.0
21
Brake Line Flared Fittings
12-15 16-21
Brake Disc Bolts Front / Rear
18.0 Front
27.0 Rear
24
36
Brake Switch 12-15 16-21
Caliper Mounting Bolts
18.0 24
Sportsman Caliper Slide Pins
30-35 41-48
Rear Master Cylinder-to-Frame Bolts
8 11
NOTE: Refer to tightening procedures in this chapter. Some special procedures are used when torquing
certain bolts and fasteners.
Component Service Limits
FRONT BRAKE CALIPER
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness .298” / 7.6 mm .180” / 4.6 mm
Brake Disc Thickness .150-.165” / 3.81-4.19 mm .140” / 3.556 mm
Brake Disc Thickness Variance
Between Measurement
–
.002” / .051 mm
Brake Disc Runout
–
.010 / .254 mm
REAR BRAKE CALIPER
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness .318” / 7.6 mm .180” / 4.6 mm
Brake Disc Thickness .180-.195” / 4.57-4.95 mm .170” / 4.318 mm
Brake Disc Thickness Variance
Between Measurements
–
.002” / .051 mm
Brake Disc Runout
–
.010” / .254 mm
BRAKES
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