Fluid Replacement/Bleeding Procedure - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION
FLUID
REPLACEMENT/BLEEDING
PROCEDURE
NOTE: When bleeding the brakes or replacing the
fluid always start with the caliper farthest from the
master cylinder.
CAUTION:
Always wear safety glasses.
CAUTION:
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces.
BRAKE BLEEDING - FLUID
CHANGE
NOTE: This procedure should be used to change
fluid or bleed brakes during regular maintenance.
A
D
1. Clean reservoir cover thoroughly.
2. Remove screws, cover, and diaphragm (C) from
reservoir.
3. Inspect vent slots (A) in cover and remove any
debris or blockage.
4. If changing fluid, remove old fluid from reservoir
with a Mity Vact (PN 2870975) or similar tool.
NOTE: Do not remove brake lever when reservoir
fluid level is low.
5. Add brake fluid to the upper level mark on
C
Left hand brake
bleeder screw
B
6. Begin bleeding procedure with the caliper that is
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 brake lever (D) until pressure builds
8. While maintaining lever pressure, open bleeder
MAX
reservoir.
Polaris DOT 3 Brake Fluid
(PN 2870990)
DH Caliper
Forward
Left Hand
Brake Line
Right hand brake bleeder screw
farthest from the master cylinder. Install a box
end wrench on caliper bleeder screw. Attach a
clean, clear hose to fitting and place the other end
in a clean container. Be sure the hose fits tightly
on fitting.
and holds.
screw. Close bleeder screw and release brake
lever. NOTE: Do not release lever before bleeder
screw is tight or air may be drawn into caliper.
Right Hand
Brake Line
9.7