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9.2
BRAKES
SPECIFICATIONS
Torque Table
NOTE: Refer to tightening procedures in this chapter. Some special procedures are used when torquing
certain bolts and fasteners.
Component Service Limits
TORQUE SPECIFICATIONS (Sportsman and X2)
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 18.0 24
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
FRONT BRAKE CALIPER (Sportsman and X2)
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 -- .002” / .051 mm
Brake Disc Runout -- .010 / .254 mm
REAR BRAKE CALIPER (X2 ONLY)
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness .298” / 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 -- .002” / .051 mm
Brake Disc Runout -- .010” / .254 mm
REAR BRAKE CALIPER (Sportsman ONLY)
ITEM STANDARD SERVICE LIMIT
Brake Pad Thickness .318” / 7.6 mm .180” / 4.6 mm
Brake Disc Thickness .150-.165” / 3.81-4.19 mm .140” / 3.56 mm
Brake Disc Thickness Variance -- .002” / .051 mm
Brake Disc Runout -- .010” / .254 mm