Without A Brake Bleeder - Polaris 1999 Sportsman 400 Service Manual

422
a. A t the front ca liper assem bly. op en the bleed
valve about onc- halft urn and pum p the brak e
bleeder.
b. At the outp ut s haft cal iper assemb ly, open the
bleed valve about one-half tum and pump the
brake bleeder.
NOTE
If air is entering the brak e bleeder
hose from around the bleed valve.
ap-
I'll' se veral laye rs ofTeflontape
/0
the
bleed
1'11h'e.
This sho uld make a good
sea l between fire bleed val ve and the
brake bleeder hose.
9 . As the fluid ente rs the sys te m and ex its into the
bra ke bleeder the leve l will drop in thc rese rvoi r.
Ma intai n the leve l at about 3/8 in. (9.5 m m) from
the
top
o f the reservo ir to preven t air from be ing
dra wn into the sys tem.
10. Conti nue to pum p the lever on the brake
b leeder until the fluid emergi ng from the hose is
co mp lete ly free of bubb les. At th is po int, tig hten the
ble ed va lve.
NOTE
Do not allow the reservoir to emp ty
during the bleeding operation or
more air will enter the sys tem. lf this
occurs, the entire procedure must be
repea ted.
I I. When the bra ke fluid is free of bub bles, tighten
the bleed valve, re mo ve the brake bleeder tube and
install the bleed va lve d ust cap.
12. If necessary, add fluid to co rrect the level in the
reservo ir. It sho uld be to the upp er level line .
13. Insta ll the diaphragm and cover and tighten the
screws
securely.
14. Test the feel of the brake lever.
It sho uld
be fi rm
and sho uld
offe r the same resistance
each time it is
o pera ted. If it fee ls spongy, it is likely that there is
sti ll a ir in the system and it mu s t be bled again.
When a ll a ir has been bled from the sys tem and the
fluid leve l is co rrec t in the reservo ir. do uble-c heck
for leaks and tighten all fitt ing s and connectio ns.
15. Install the rear lender and cha in guard as de-
sc ribed in Chapter Fifteen,
WAR NING
Bef ore riding the ATV, make certain
tha t
tire brak e is opera ting correctly
C HA I'TE R FO URTEEN
by operating the lever anil p edal sev-
eral times .
16. Test ride the ATV slow ly at first to ma ke sure
that the brakes a rc op erating pro perl y.
Withuut a Brake Bleeder
I. Park the vehicle on level g round and bloc k the
whee ls so the ve hicle ca nnot roll in either d irec tio n.
2. Remove the rear fender and right -side footwc ll
as described in Chapter Fifteen .
3. Rem ove the du st eap( s) from the bleed valve o n
the caliper assem blies .
4 . Co nnec t a len gth of clear tubing and wrench to
the bleed va lve o n the calipe r assembly. Refer to
Fig ure 9 1 for the front and Fi gu re 92 for the rear.
5. Place the other end of the tube into a clean con-
tain er. Fi ll the co nta iner w ith enou gh fresh brake
lluid to kee p the cnd submerged. The tube should be
long enoug h so that a loop ca n he made higher than
the bleed va lve to preven t air from being drawn into
the ca lipe r during bleedi ng.
CAUTION
Cover the surro unding area s ' w ith a
heavy clot h orplastic tarp to protect
it
.Ii"01/I
the accidental spilling of brake
.fluid. Wash
any
hrake.fluid
offof
011.1'
pla stic. painted or plated surface im-
media tel y; as it will destroy
thefinish.
Use soapy water and rinse com-
pie/ely.
6A . On the fro nt maste r cy linder, perform the fol-
lowin g:
a. Clean the top of the master cy linde r cover of
all de bri s.
h. Re move the screws sec uring the to p co ver
(Fi gu re 93).
c. Remove the top cover and di aphra gm from
the ma ster cylind er.
68 . On I998-on rear mas ter cy linder, un screw the
co ver (Fi g ure 94) and remove the dia phra gm from
the reservoir.
7. Fill the reservoirs almost to the top lip; insert the
diaphragm and the cover loosely. Lea ve the cover in
place du rin g this procedure to prevent dirt en tering.
WARNING
Use brake f luid from a sealed con-
tainer marked DOT
3
011/.1' (specified