Polaris TRAIL BOSS 2003

BRAKES
9.2
SPECIFICATIONS
Front Brake Cal iper
Item Standard Service Limit
Brake Pad Thickness .298 ± .0073² /7.56± .185 mm .150² /3.81mm
Brake Disc Thickness .150-.165² / 3.810-4.191 mm .140² / 3.556 mm
Brake Disc Thickness Variance Between
Measurements
- .002² / .051 mm
Brake Disc Runout - .020² /.50mm
Rear Brake Caliper
Item Standard Service Limit
Brake Pad Thickness .270 ± .005² /6.85± .127 mm .150² /3.81mm
Brake Disc Thickness .177--.188² / 4.49--4.77 mm .167² / 4.242 mm
Brake Disc Thickness Variance Between
Measurements
- .002² / .051 mm
Brake Disc Runout - .010² /.25mm
Master Cylinder I.D. .750²
TORQUE SPECIFICATIONS
Item Torque
(ft. lbs. except where noted*)
Torque
(Nm)
Front Caliper Mounting Bolts 18.0 25
Rear Caliper Mounting Bolts 28 38
Master Cylinder Mounting Bolts *25 in. lbs. 3.0
Master Cylinder Reservoir
Cover Bolt
*5 in. lbs. .56
Brake Line Banjo Bolt 15.0 21
Front Brake Disc 18.0 25
Front Wheel Mounting Nuts 20.0 28
NOTE: Refer to the tightening procedures in this chapter when torquing the bolts. Some special procedures are
used when torquing certain bolts and fasteners.