Service Manual

11.6
BRAKES
BRAKE BLEEDING
Fluid Replacement
NOTE: When bleeding the brakes or replacing the
fluid, always start with the caliper farthest from the
master cylinder.
This procedure should be used to change fluid or bleed brakes
during regular maintenance.
1. Clean reservoir cover thoroughly.
2. Remove screws, cover and diaphragm from master cylinder
reservoir.
3. Inspect vent slots in cover and remove any debris or
blockage.
4. If changing fluid, remove old fluid from reservoir and lines
at the bleeders with a Mity Vac™ or similar tool.
NOTE: Do not move brake lever when reservoir fluid
level is low.
5. Add brake fluid to .25” - .30” (6 - 8 mm) from the top of
the reservoir.
Bleeding Procedure
Front Brake System Bleeding
1. Remove the reservoir cover from the hand brake master
cylinder and verify fluid is at specified level.
2. If fluid level is low, add brake fluid to .25” - .30” (6 - 8 mm)
from the top of the reservoir.
3. Install a box end wrench on foot master cylinder bleeder
screw. Attach a clean, clear hose to fitting and place the
other end in a container. Be sure the hose fits tightly on
fitting.
NOTE: Install diaphragm and cover onto the hand
master cylinder reservoir to prevent spills. Do not
tighten the cover.
4. Slowly pump the hand brake lever until pressure builds and
holds.
5. While maintaining lever pressure, open bleeder screw.
6. Close bleeder screw and release brake lever
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.
7. Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
8. Tighten bleeder screw securely and remove bleeder hose.
Torque the bleeder screw to 47 in. lbs. (5.3 Nm).
CAUTION
Always wear safety glasses during
these procedures.
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact with
finished surfaces.
Screws
Cover
Diaphragm
Master
Cylinder
.25” - .30” (6 - 8 mm)
From Top of Reservoir
Polaris DOT 4 Brake Fluid
PN: 2872189
CAUTION
Maintain at least 1/2” (1.27 cm) of brake fluid
in the reservoir to prevent air from
entering the master cylinder.
Bleeder
Screw
Foot Master Cylinder