Brake System; General Guidelines - Polaris 600 RUSH 2010 Manual

Final Drive/Brake System

BRAKE SYSTEM

General Guidelines

WARNING
An unsafe condition exists when air is trapped in the
hydraulic brake system. Air in the brake hydraulic
system acts like a soft spring and absorbs a large
percentage of the pressure developed by the master
cylinder. Without this pressure, the braking system
cannot develop full braking force to allow for safe,
controlled stops. It is extremely important to bleed the
brakes properly after any brake system work has been
performed or when inspection reveals spongy brakes.
A soft, spongy feeling in the brake lever and/or brake
pedal could indicate a hazardous condition in the brake
system. Do not operate the vehicle until the failure in
the brake system is corrected.
Keep brake fluid tightly sealed and out of reach of
children. Brake fluid can accumulate moisture,
reducing its effectiveness.
Contaminated brake discs or brake pads greatly
reduce braking performance and increase stopping
distance. Do not attempt to clean contaminated pads.
Replace them. Clean the brake disc with brake cleaner.
This brake system requires ethylene-glycol based fluid
(DOT 4). Do not use or mix different types of fluid such
as silicone-based or petroleum-based.
Do not use brake fluid taken from old, used or unsealed
containers. Never reuse brake fluid.
CAUTION
Pressure bleeding is not recommended. When fluid
surges through the fittings, it is possible to cavitate the
fluid and create air in the system. In addition, the fluid
stored in a pressure bleeder may be contaminated. Al-
ways use fresh DOT 4 brake fluid from a sealed con-
5.20
tainer.
Keep these points in mind when bleeding hydraulic
brakes:
• The master cylinder reservoirs have limited
capacities. It is easy to empty them during the
bleeding procedure. This introduces air into the
system which you are trying to purge. Watch the
reservoir closely and add fluid when necessary to
prevent air from entering the system.
• Apply only light to moderate pressure to the lever
or pedal when bleeding the brake system.
Extreme pressure will cause a surge of fluid
through the small orifices of the brake system
when the bleeder screw is opened and introduce
air into the system by means of cavitation.
• Small amounts of air can become trapped in the
banjo bolt fittings at the master cylinder(s) and
junction points of brake lines. These fittings can be
purged of air by following a standard bleeding
procedure at these fittings (instead of the bleed
screw on caliper) if necessary to speed the
bleeding process. This is usually only needed if
system was completely drained of fluid. Bleed
each line connection, starting with the fitting
closest to the master cylinder, working toward the
caliper, and ending with the bleed screw.
• Always torque banjo bolts and other brake system
fittings to specified torque.
• Change fluid every 2 years, or when fluid is dark or
contamination is suspected.