Brake Fluid Replacement & Bleeding - Polaris 600 RUSH 2010 Manual

Final Drive/Brake System
Brake Fluid Replacement & Bleeding
Each hydraulic brake is fitted with a bleeder valve and a
banjo bolt. The bleeder valve is a special screw, which
seals when tightened to the correct torque, but which
allows air and/or fluid to pass out through a hole in the
valve stem when loosened one turn.
NOTE: A second person is usually needed to assist in
bleeding the brakes.
1. Clean the master cylinder cover and remove.
2. Attach one end of a flexible tube over the stem of the
bleeder valve.
NOTE: A 'box end' wrench placed on the bleeder
valve before attaching the flexible tubing is a
convenient method for loosening and tightening the
bleed valve.
3. Place the other end of flexible tube into a jar
containing a small amount of clean fluid. See that the
end of the tube is below the fluid surface to prevent
breathing/sucking air back into the system.
4. Loosen bleeder valve one turn.
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5. Fully apply the brake and hold, check for air bubbles
rising in the fluid, indicating that air is being forced out
of the system.
6. Continue actuating the brake until air bubbles stop.
This indicates that the brake has been bled
successfully.
NOTE: Add new fluid to the master cylinder reservoir
as needed.
7. Retighten the bleeder valve when the brake lever has
reached the end of its stroke. Torque bleeder to
specification.
Brake Caliper Bleeder Screws:
Phantom: 100-135 in-lbs (11-15Nm)
Phantom Lite: 36-46 in-lbs (4-5Nm)
8. Evaluate the brake system for proper operation, and
inspect for leaks. The brake lever should feel firm,
without excessive travel and sponginess.
9. Add new fluid to the master cylinder reservoir to bring
the fluid level back up to a level between the maximum
and minimum fill lines. Replace master cylinder cover.
Master Cylinder Cover Screws:
Combined: 16-20 in-lbs (1.8-2.3Nm)
Cyclone: 6-8 in-lbs (.7-.9Nm)
CAUTION
Caution: Take care not to get brake fluid on pads or disc.
If brake fluid gets on disc, fully clean disc with alcohol.
10. Test brake system prior to returning vehicle to service.
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