Brake Bleeding; Fluid Replacement; Bleeding Procedure - Polaris 2009 Sportsman XP 850 Service Manual

BRAKES

BRAKE BLEEDING

Fluid Replacement

NOTE: When bleeding the brakes or replacing the
fluid, always start with the caliper farthest from the
master cylinder.
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.
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.
Cover
Diaphragm
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.
.25" - .30" (6 - 8 mm)
From Top of Reservoir
11.6
CAUTION
Screws
Master
Cylinder
Polaris DOT 4 Brake Fluid
PN: 2872189

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.
Bleeder
Screw
Foot Master Cylinder
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.
CAUTION
Maintain at least 1/2" (1.27 cm) of brake fluid
in the reservoir to prevent air from
entering the master cylinder.
8. Tighten bleeder screw securely and remove bleeder hose.
Torque the bleeder screw to 47 in. lbs. (5.3 Nm).