Dual Hydraulic Caliper Bleeding - Polaris Sportsman 400 Service Manual

DUAL HYDRAULIC CALIPER BLEEDING

This caliper is a dual opposed piston design, with two independent hydraulic systems contained in the same cali-
per body (see Ill.1). The caliper pistons are T-shaped, which allows both hand and foot brake to use the same
caliper piston, but remain separated by seals. The hand brake system applies hydraulic pressure to both front
calipers and only the outer diameter of the rear caliper pistons. The auxiliary (foot) brake applies pressure to the
inner portion of the rear caliper pistons. Because the hand and foot brake hydraulic systems are separate, there
are also two bleed screws -- one for the outer fluid chamber (hand brake), and one for the inner fluid chamber
(foot brake). The basic procedure for bleeding the brake system is the same as outlined on page 9.7 - 9.8; howev-
er, each system must be bled separately.
Hydraulic Auxiliary Brake inspection and adjustment is outlined on page 9.6.
DH CALIPER TOP VIEW
Foot Brake
Bleed Screw
Hand
Brake Line
Foot
Brake Line
Ill. 1
NOTE: Caliper style and location of brake lines and bleeder screws may differ
Uppermost (inner) bleed screw and brake line is for hand brake
system.
Lower (outer) bleed screw and brake line is for auxiliary (foot)
brake system.
- projex@inbox.lv -
Hand Brake Bleed
Fitting
Sealing "O" Rings
Pad
Spacer
Piston
Seals
Bleeder (Hand Brake) positioned
innermost (higher) on caliper
Bleeder (Foot Brake)
is outermost (lower)
on caliper
Brake Lever (Handlebar
Brake Pedal (Foot)
Cutaway View Of DH Caliper
Ill. 2
Upper Bleed
Screw
Hand Brake
Lower Bleed
Screw
Auxiliary Brake
BRAKES
Line in from
hand brake
master cy-
linder
Line in
from foot
brake
master cy-
linder
)
9.5