Service Manual

9.6
BRAKES
BRAKE BLEEDING / FLUID CHANGE
NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the
master cylinder.
1. Clean master cylinder reservoir cover thoroughly and
remove the cover.
2. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
3. Add brake fluid to the indicated MAX level of reservoir.
4. Begin bleeding procedure with the caliper that is farthest
from the master cylinder. Install a box end wrench on
caliper bleeder screw. Attach a clean, clear hose to fitting
and place the other end in a clean container. Be sure the
hose fits tightly on fitting.
5. Have an assistant slowly pump foot pedal until pressure
builds and holds.
6. Hold brake pedal on to maintain pedal pressure, and open
bleeder screw. Close bleeder screw and release foot pedal.
NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
cylinder.
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 bleeder screw to 47 in. lbs. (5.3 Nm).
9. Repeat procedure Steps 5 - 8 for the remaining calipers.
10. Add brake fluid to MAX level inside reservoir.
11. Install master cylinder reservoir cover.
12. Field test machine at low speed before putting into service.
Check for proper braking action and pedal reserve. With
pedal firmly applied, pedal reserve should be no less than
1/2"(1.3 cm).
13. Check brake system for fluid leaks.
CAUTION
Always wear safety glasses.
CAUTION
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces. This procedure should be used to
change fluid or bleed brakes during
regular maintenance.
Mity Vac™ (PN 2870975)
Polaris DOT 4 Brake Fluid
(P/N 2872189)
Master Cylinder
Remove
Cover
CAUTION
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
entering the master cylinder.
Master Cylinder Fluid Level
Between the MIN and MAX line shown
on the reservoir.