Dual Hydraulic Brake Caliper Bleeding - Polaris Magnum 2x4 Service Manual

BRAKES
Dual Hydraulic Brake Caliper
Dual Hydraulic Caliper Bleeding
The new Dual Hydraulic or "DH" rear brake caliper is used on the 1998 Sportsman 500 and 1998 Scrambler 400 and 500.
This caliper is a dual opposed piston design, with two independent hydraulic systems contained in the same caliper body
(see 111.1). 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
diam-
eter 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 9.4 - 9.5, however, each system must be bled separately.
Hydraulic Auxiliary Brake inspection and adjustment is outlined on page 9.30b.
Foot Brake
Bleed Screw
Foot
Brake Line
TOP VIEW Hand Brake Bleed
Fitting
/ '
Sealing "0" Rings
':. ':.
~
-------."
II
"
,I
. 1
. :
I.
'!.J
Piston
Seals
Bleeder (Hand Brake)
positioned
higher on caliper)
Brake Pedal (Foot
Line in from
hand brake
master cylinder
III. 1 III. 2
Cutaway View Of DB Caliper
NOTE: Caliper style and location of brake lines and bleeder screws may differ
Upper bleed screw and brake line (A) is for hand brake system.
Lower bleed screw and brake line (B) is for auxiliary (foot) brake
system.
Polaris Industries Inc.
9.30a
Scrambler Style DH Caliper
5/98