Specifications; Torque Table; Component Service Limits - Polaris 2008 sportsman 800efi Service Manual

BRAKES

SPECIFICATIONS

Torque Table

TORQUE SPECIFICATIONS (Sportsman and X2, Touring)
Front / Rear Caliper Mounting Bolts
Handlebar Master Cylinder Clamp Bolts
Hand Master Cylinder Reservoir Cover Screws
Brake Line Flared Fittings
Brake Disc Bolts Front / Rear
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

FRONT BRAKE CALIPER (Sportsman and X2, Touring)
I
TEM
Brake Pad Thickness
Brake Disc Thickness
Brake Disc Thickness Variance
Brake Disc Runout
I
TEM
Brake Pad Thickness
Brake Disc Thickness
Brake Disc Thickness Variance
Brake Disc Runout
I
TEM
Brake Pad Thickness
Brake Disc Thickness
Brake Disc Thickness Variance
Brake Disc Runout
9.2
I
TEM
Brake Line Banjo Bolt
Brake Switch
S
TANDARD
.298" / 7.6 mm
.150-.165" / 3.81-4.19 mm
REAR BRAKE CALIPER (X2, Touring ONLY)
S
TANDARD
.298" / 7.6 mm
.180-.195" / 4.57-4.95 mm
REAR BRAKE CALIPER (Sportsman ONLY)
S
TANDARD
.318" / 7.6 mm
.180-.195" / 4.57-4.95 mm
T
ORQUE FT
--
--
--
--
--
--
. . ( . .) T
LBS IN LBS
18
(25 in.lbs.)
(7 in.lbs.)
15.0
12-15
18.0 Front
27.0 Rear
12-15
18.0
30-35
8
S L
ERVICE IMIT
.180" / 4.6 mm
.140" / 3.556 mm
.002" / .051 mm
.010 / .254 mm
S L
ERVICE IMIT
.180" / 4.6 mm
.170" / 4.318 mm
.002" / .051 mm
.010" / .254 mm
S L
ERVICE IMIT
.180" / 4.6 mm
.170" / 4.318 mm
.002" / .051 mm
.010" / .254 mm
N
ORQUE M
24
3.0
0.79
21
16-21
24
36
16-21
24
41-48
11