Master Cylinder Disassembly - Polaris Trail Boss 330 2003 Service Manual

BRAKES
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.
11. Repeat procedure Steps 5-9 for the remaining
caliper(s).
12. Add brake fluid to the proper level.
Master Cylinder Fluid Level:
MAX level inside reservoir
Sight glass must look dark, if sight
glass is clear, fluid level is too low
13. Install diaphragm, cover, and screws. Torque the
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
DISASSEMBLY
1. Clean master cylinder and reservoir assembly.
Make sure you have a clean work area to
disassemble brake components.
2. Place a shop towel under brake line connection at
master cylinder. Loosen banjo bolt; remove bolt
and sealing washers.
CAUTION:
Brake fluid will damage finished surfaces. Do not
allow brake fluid to come in contact with finished
surfaces.
9.7