Master Cylinder Removal - Polaris SPORTSMAN 600 2003 Service Manual

BRAKE BLEEDING CONT'D
NOTE: Fluid may be forced from supply port (B) when
brake lever is pumped.
reservoir to prevent spills. Do not install cover. See
Illustration above.
7. Slowly pump brake lever (D) until pressure builds
and holds.
8. 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.
Bleeder Screw Torque
25- -30 in.lbs. (2.80 - -3.40 Nm)
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 1/2² (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. Torque the bleeder screw to 25--30
in.lbs. (2.80 --3.40 Nm).
11. Repeat procedure Steps 5-9 for the remaining
caliper(s).
12. Add Polaris Dot 3 Brake Fluid (PN 2870990) to
MAX level inside reservoir.
Master Cylinder Fluid Level:
MAX level inside reservoir
Sight glass must look dark, if sight
glass is clear, fluid level is too low
9.6
Place diaphragm (C) in
13. Install diaphragm, cover and screws. Tighten
screws to 5 in. lbs. (0.56 Nm).
Reservoir Cover Torque -
5 in. lbs. (0.56 Nm)
14. 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 1/2² (1.3 cm) from
handlebar.
15. 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.
BRAKES BRAKES