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Polaris 2004-2005 Sportsman 6x6 - Specifications

Polaris 2004-2005 Sportsman 6x6
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GENERAL INFORMATION
9.2
SPECIFICATIONS
Item Standard Service Limit
Brake Pad Thickness .298 ± .0073 /7.56± .185 mm .180 /4.6mm
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.

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