Master Cylinder; Removal - Polaris Outlaw 500 Service Manual

BRAKES
5. Install a box end wrench on the upper rear 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.
Bleeder Screws
6. Slowly pump foot brake lever until pressure builds and
holds.
7. While maintaining lever pressure, open bleeder 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.
8. Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
9. Tighten bleeder screw securely and remove bleeder hose.
Torque bleeder screw to 27 in. lbs. (3.1 Nm).
10. Using a funnel, add brake fluid to the MAX level mark on
reservoir.
Rear Reservoir Fuild Level:
Add to MAX level shown on the outside
of the rear reservoir.
6.10
11. Field test machine at low speed before putting into service.
Check for proper braking action and lever reserve. With
lever firmly applied, lever reserve should be no less than
1/2" (1.3 cm) from handlebar.
12. Check brake system for fluid leaks and inspect all hoses and
lines for wear or abrasion. Replace hose if wear or abrasion
is found.

MASTER CYLINDER

Removal

1. Clean master cylinder and reservoir assembly. Make sure
you have a clean work area to disassemble brake
components.
2. Place a shop towel under brake line connection at master
cylinder. Loosen banjo bolt (A); remove bolt and sealing
washers.
A
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
3. Loosen the master cylinder clamp bolts (B) on the
handlebar side of the master cylinder.
B
CAUTION
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