Brake Bleeding / Fluid Change - Polaris 2008 RZR Service Manual

BRAKES

BRAKE BLEEDING / FLUID CHANGE

NOTE: When bleeding the brakes or replacing the
fluid always start with the furthest caliper from the
master cylinder.
Always wear safety glasses.
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces. This procedure should be used to
change fluid or bleed brakes during
regular maintenance.
1. Clean master cylinder reservoir cover thoroughly and
remove the cover.
Master Cylinder
Remove
Cover
2. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ pump or similar tool.
Mity Vac™ (PN 2870975)
3. Add brake fluid to the indicated MAX level of reservoir.
Polaris DOT 4 Brake Fluid
(P/N 2872189)
9.6
CAUTION
CAUTION
4. 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.
5. Have an assistant slowly pump foot pedal until pressure
builds and holds.
6. Hold brake pedal on to maintain pedal pressure, and open
bleeder screw. Close bleeder screw and release foot pedal.
NOTE: Do not release foot pedal before bleeder
screw is tight or air may be drawn into master
cylinder.
7. Repeat procedure until clean fluid appears in bleeder hose
and all air has been purged. Add fluid as necessary to
maintain level in reservoir.
Maintain at least 1/2"(1.27 cm) of brake fluid in
the reservoir to prevent air from
entering the master cylinder.
8. Tighten bleeder screw securely and remove bleeder hose.
Torque bleeder screw to 47 in. lbs. (5.3 Nm).
9. Repeat procedure Steps 5 - 8 for the remaining calipers.
10. Add brake fluid to MAX level inside reservoir.
Master Cylinder Fluid Level
Between the MIN and MAX line shown
on the reservoir.
11. Install master cylinder reservoir cover.
12. Field test machine at low speed before putting into service.
Check for proper braking action and pedal reserve. With
pedal firmly applied, pedal reserve should be no less than
1/2"(1.3 cm).
13. Check brake system for fluid leaks.
CAUTION