Disc Brake Fluid Level Check And Fill; Disc Brake Hoses - Polaris 1999 Sportsman 400 Service Manual

L UBRICATION, M AINTENANCE AND T UN E-VI'
71
®
I. Place the ATV on leve l gro und and set the park-
ing brake.
2. Clean any dirt from the are a around the cove r
prior to remo ving the cove r.
NO TE
To
control the small flo w ofhydruulic
fluid. punch
a small hole
into
the seal
of
a nell' container
ofbrakefluid
next
to the edg e ofthe pour spo ut. This
will
help eliminate fluid sp iliage , espe-
ciatl y while
addin g
fluid to the
vel}'
small rese r voirs.
II
Visua lly inspect each brake disc for cracks, deep
scoring, heat distorti on, checking and excessive
wear. Inspect the brake pads for uneven wear (Fig-
ure
47.
typical) and ov erheating. Install new brake
pads i fworn to the brake pad service limit groove or
to
the dimension listed in Table 6.
Bleeding the sys tem, servi cing the brake sys tem
components and replacing the brake pads arc cov-
ered in Chapter Fourte en .
Disc Brake Flui d Level
C heck and Fill
Maintain thehydraulic brake fluid in the reservoir
at its
ma ximum level. lf
necessary, correct the level
by adding fresh brake fluid.
CAUTION
Do
I/O !
spill brake flu id
Oi l
plastic.
painted or plated surfaces. as
it
witt
destroy the
fi nish. ftlish offthe area
immedi ately with soapy water
and
thoroughly rinse it
offwuh
clean
water:
WARNING
Use brakefluid clearly marked
DOT3
from
II
sealed
container:
Other Op es
may vaporize and ca use brak efailure.
A lways
use the same brand name; do
1101
intermix as many bra nds are
not
comp atible. Do not intermix sili-
cone- based (DOT 5) brakefluid, as it
can cause brake component dama ge
leading to brake sys tem fa ilure.
3A. O n the fron t ma ster cy linder, perform the fo l-
lowing:
a. Position the handlebar so the front master cy l-
inder is horizontal.
b. Remove the screws securing the reservoircap
and remove the reservoir cover (Figure 48).
c.
Refill the master cylinder reservoir, ifncecs-
sary, to maintain the
correct
fluid level as in-
dicated on the side of the reservoir.
d . Install the diaphragm and cover. Tighten the
cover screws securely.
3B. On the rear mastercylinder,
perform
the following:
a. Remove the scat as described in Chapt er Fif-
teen.
b. Unscrew and remove the reservoir cap (Flg -
ure 49) .
c. Refi ll the remote reservoir. if necessary. to
maintain the correct fluid level as indicated
011
the side of the reservoir.
d. Insta ll the reservoir cap and tighten securely.
Disc Brake Hoses
Check the brake hoses between the master cylin-
der and each brake caliper assembly. If there is any
leakage, tight en the connections and bleed the
brakes as described under Bleeding the System in