Polaris 1999 Sportsman 400 Service Manual page 419

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BRAKES
®
1.
Banjo
bo
lt
2.
Sealing
wash er
3.
Upp er
ho
se
4.
Brake light
switch
5. Outp
ut shaft
caliper
hos
e
6.
Four-way
connector
7. Front
ca
liper
right
side ho
se
8.
Scr ew
9.
Front
caliper
left
side
hos
e
B
R A KE
H
OSES
1
2 3
2
~
~
0
~
5
I
I
L
413
4.
Clean
the
top
ofthe
master
cylinder
of all
debris.
5.
Remove
the
screws securing
the
top
cover
(A,
Figu re 62)
.
6.
Remo
ve
the
lop cove
r
and diaphrag m
from the
master cyl
inder.
7.
Use a
clean
syri
nge
to
remove the brake
fluid
from the
reservoir.
Discard
the
brake
flu
id.
8.
Slide the
rubber boot (F
igu re
63) ofT the brake
hose
fitting.
9.
Remove
the banjo
bo lt
and
scaling
was
hers (B,
Figu
re
62)
securing
thc upper brake hose to the
master
cylinder.
Place the loose
end
of
the
upper
brake
hose
in
a
reclosab le
plastic
bag
and
close
it
to
prevent contamination and the discha rge
of
brake
fluid.
Secure
the hose to the
ha
ndlebar
in the upright
position.
10. Disconn ect
the
brake hose
from
the upper
fit-
ting
on the
four-way
connec tor (A,
Figure
75).
I
I.
Remove
any tic
wraps
securing
the
brake hose
to
the
chassis.
12.
Note
the routing
of
the brake
hose
through the
frame.
The brak
e
hose
must
follow
the
exact
same
path
when
installed
to
avoid
any
kinks
or
dama
ge.

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