Service Manual

2.31
MAINTENANCE
2
BRAKE SYSTEM
Brake Fluid Inspection
The following checks are recommended to keep the brake
system in good operating condition. Service life of brake system
components depends on operating conditions. Inspect brakes in
accordance with the maintenance schedule and before each ride.
• Keep fluid level in the hand master cylinder reservoir to
the indicated level inside reservoir.
• Check the fluid level “eye”. If it is clear, it is an
indication that fluid is needed or the brake pads may be
worn, which can reduce the fluid level.
• If required, add brake fluid to .25” - .30” (6 - 8 mm)
from the top of the reservoir.
• Check the fluid level of the auxiliary brake master
cylinder reservoir. Add fluid to the indicated level.
• Use Polaris DOT 4 Brake Fluid (PN 2872189).
• Check brake system for fluid leaks, excessive travel or
spongy feel.
• Check brake pads for wear, damage or looseness.
• Check surface condition of the disc.
• Inspect thickness of brake pad friction material.
Brake Pad Inspection
Inspect brake pad friction material for excessive wear.
Hose / Fitting Inspection
Check brake system hoses and fittings for cracks, deterioration,
abrasion, and leaks.Tighten any loose fittings and replace any
worn or damaged parts.
Fluid Level “Eye”
Full
Low
.25” - .30” (6 - 8 mm)
From the Top of Reservoir
CAUTION
DO NOT OVERFILL!
Excess brake fluid may cause brake drag.
Fill to the indicated fill line or specification.
Figure 2-31
Brake Pad Inspection
Brake Pad
Measure
Thickness
Service Limit - .040” (1 mm)