Polaris 1999 Sportsman 400 Service Manual page 427

BRAKES 42 1
6. Fill the reservo irs almost to the top lip; insert the
diaphragm and the cove r loosely. Leave the cove r in
place during this procedure to prevent dirt from en-
tering.
WARNING
Use brake
fluid fro
m a sealed con-
tain er marked DOT
3
only (sp ecified
for
disc brakes). Other
types
may l-'a-
p orize
andcause brakef ailure. Do flat
intermix different braw l," or types;
they may
not
be compatible.
7. If the front master cyli nder was drained, it must
be bled be fore bleeding the entire syste m. Pcrfonn
the following:
a. Remove the brake hose fromthe master cy
lin-
der as described in this chapter. Tic the loose
end of the hose up to the handlebar or frame.
b. Place severa l shop cloths under the master
cylinder to catch the expelled brake fluid.
e. Ho ld a thumb over the brake hose ho le in the
master cylinder and fill the
reservoir
with
DOT 3 brake flu id. Do not remove the thumb .
d. Wh ile holding a thumb over the hole, pump
the brake lever or pedal several times. Then
hold the lever or pedal in the depressed posi-
tion.
e. Red uce thumb pressure on the brake hose
hole. Som e brake fluid and air bubb les will
leak out. Reapply thumb pressure.
f. Repeat subs teps d and e until no air bubble s
bleed out of the hole and there is resistance
felt at the lever or pedal.
g. Cheek the reservoir fluid level and top it off if
necessary.
h. Reconnect the brake hose onto the master cyl-
inder. Tighten the brake hose fitting to the
torque specifi cation listed in Ta ble 2.
i. Wash
oft' any spilled brake fluid before con-
tinuing.
CA UTION
The bleed screws are made
of
a rela-
tive ly soft metal .
If
they are tight.first
loosen the bleed screw with a o-point
so cket, then lise a 1/4 in.
wrench
to
open and clos e them.
8. Open the following bleed valves: