Brake Bleeding - Fluid Change - Polaris 2003 Pro X Service Manual

CHASSIS/BRAKES/FINAL DRIVE

Brake Bleeding - Fluid Change

Brake Bleeding - Fluid Change
This procedure should be used to change fluid or bleed brakes during regular maintenance, or after complete
brake service. Brake fluid may damage painted or plastic surfaces. Take care not to spill, and wipe up any spills
immediately. Cover parts to avoid damage.
1. Clean reservoir cover thoroughly.
2. Remove screws, cover, and diaphragm from
reservoir.
3. Inspect vent slots (A) in cover and remove any
debris or blockage.
4. If changing fluid, remove fluid from reservoir with a
Mity Vac pump or similar tool.
NOTE: Do not remove brake lever when reservoir fluid
level is low.
Mity Vac
5. Add brake fluid to within 1/4-5/16 (.6-.8 cm) of
reservoir top.
Reservoir Cover Screw Torque -
15-18 in. lb. (1.7-2 Nm)
6. Install a box end wrench on caliper bleeder screw fitting. Attach a clean, clear hose to fitting and place the
other end in a clean container. Be sure the hose fits tightly on fitting.
NOTE: Fluid may be forced from compensation port (B) when brake lever is pumped. Place diaphragm (C) in
reservoir to prevent spills. Do not install cover.
7. Slowly pump lever (D) until pressure builds and holds.
8. While maintaining lever pressure, open bleeder screw. Close bleeder screw and release brake lever. Do not
release lever before bleeder screw is tight or air may be drawn into caliper.
9. 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.
10. Tighten bleeder screw securely and remove bleeder hose.
11. Add brake fluid to the proper level.
12. Install diaphragm, cover, and screws. Tighten screws to specification.
5.8
PN 2870975
A
D
Polaris DOT 3 Brake Fluid
PN 2870990
Polaris DOT 3 High Temp Fluid
(for Racing applications)
PN 2873717
C
B