Specifications; Special Tools; Torque Table; Component Service Limits - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

SPECIFICATIONS

Special Tools

Bosch Automotive Service Solutions: 1-800-345-2233 or http://polaris.service-solutions.com/

Torque Table

ITEM
Front / Rear Caliper Mounting Bolts
Handlebar Master Cylinder Clamp Bolts
Hand Master Cylinder Reservoir Cover Screws
Brake Line Banjo Bolt
Brake Line Flared Fittings
Brake Disc Bolts Front / Rear
Brake Switch
Caliper Mounting Bolts
Sportsman Caliper Slide Pins
Rear Master Cylinder-to-Frame Bolts
NOTE: Refer to tightening procedures in this chapter. Some special procedures are used when torquing
certain bolts and fasteners.

Component Service Limits

ITEM
Brake Pad Thickness
Brake Disc Thickness
Brake Disc Thickness Variance
Between Measurement
Brake Disc Runout
ITEM
Brake Pad Thickness
Brake Disc Thickness
Brake Disc Thickness Variance
Between Measurements
Brake Disc Runout
TORQUE SPECIFICATIONS
FRONT BRAKE CALIPER
STANDARD
.298" / 7.6 mm
.150-.165" / 3.81-4.19 mm
–
–
REAR BRAKE CALIPER
STANDARD
.318" / 7.6 mm
.180-.195" / 4.57-4.95 mm
–
–
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.
TORQUE FT-LBS (IN-
TORQUE NM
LBS)
18 24
(25 in-lbs)
3.0
(7 in-lbs)
0.79
15.0
21
12-15 16-21
18.0 Front 24
27.0 Rear 36
12-15 16-21
18.0 24
30-35 41-48
8 11
SERVICE LIMIT
.180" / 4.6 mm
.140" / 3.556 mm
.002" / .051 mm
.010 / .254 mm
SERVICE LIMIT
.180" / 4.6 mm
.170" / 4.318 mm
.002" / .051 mm
.010" / .254 mm
BRAKES
9
9.3