Brake Bleeding / Fluid Change - Polaris SPORTSMAN 600 2003 Service Manual

BRAKES
NOTE: Uppermost (inner) bleed screw and brake line
(A) is for hand brake system. Lower (outer) bleed screw
and brake line (B) is for auxiliary (foot) brake system.
Outer Bleed Screw
Auxiliary Brake
B
B
BRAKE BLEEDING - FLUID
CHANGE
NOTE: When bleeding the brakes or replacing the
fluid, always start with the caliper farthest from the
master cylinder.
CAUTION:
Always wear safety glasses during these
procedures. Brake fluid will damage finished
surfaces. Do not allow brake fluid to come in
contact with finished surfaces.
NOTE: Do not remove brake lever when reservoir
fluid level is low.
This procedure should be used to change fluid or
bleed brakes during regular maintenance.
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.
A
D
Inner Bleed Screw
Hand Brake
A
Sight
C
Glass
B
4. If changing fluid, remove old fluid from reservoir
with a Mity Vact pump or similar tool.
Mity Vact (PN 2870975)
5. Add brake fluid to the indicated MAX level inside
reservoir.
MAX
Polaris DOT 3 Brake Fluid
(PN 2870990)
6. Begin bleeding procedure with the caliper that is
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. (E) is Auxiliary Brake Line, (F) is Hand
Brake Line.
Outer Bleed Screw
Auxiliary Brake
B
E
Inner Bleed Screw
Hand Brake
F
9.5