Polaris Sportsman XP 1000 S 2020 - Chapter 10 Brake System

10
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
10.1
BRAKE SYSTEM
CHAPTER 10
BRAKE SYSTEM
GENERAL INFORMATION.. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...10.3
GENERAL BRAKE SPECIFICATIONS . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ...10.3
SPECIAL TOOLS / BRAKE FLUID. .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . .. . .10.3
BRAKE SYSTEM SERVICE NOTES . . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . .10.4
BRAKE SYSTEM OPERATION . ... . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..10.4
BRAKE SYSTEM (DOMESTIC MODELS) . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . .10.5
BRAKE SYSTEM ASSEMBLY VIEW . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . .10.5
FRONT CALIPER ASSEMBLY VIEW. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . .10.7
REAR CALIPER ASSEMBLY VIEW . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ..10.8
FRONT BRAKE MASTER CYLINDER ASSEMBLY VIEW . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .10.9
BRAKE LINE ROUTING . . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.10
BRAKE SYSTEM (INTERNATIONAL MODELS). . ... . ... . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... 10.11
BRAKE FLUID FLOW... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 10.11
BRAKE SYSTEM ASSEMBLY VIEW . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... 10.13
FRONT CALIPER ASSEMBLY VIEW. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. 10.15
REAR CALIPER ASSEMBLY VIEW . ... . ... . ... . . .. . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . 10.16
FRONT BRAKE MASTER CYLINDER ASSEMBLY VIEW . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 10.17
BRAKE LINE ROUTING . . . .. . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.18
BRAKE WARNING SYSTEM OVERVIEW . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.19
BRAKE WARNING SYSTEM INSPECTION . . ... . ... . .. . . ... . ... . . .. . ... . ... . ... . .. . . ... . ... . ... . ... 10.19
HAND BRAKE MASTER CYLINDER SWITCH INSPECTION / TESTING.. . . .. . . ... . ... . ... . .. . . .. . . . 10.19
BRAKE PRESSURE SWITCH INSPECTION / TESTING. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . ... . . .. 10.20
BRAKE FLUID BLEEDING .. . . .. . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. . . .. . . . 10.21
FRONT BRAKE SYSTEM BLEEDING... . ... . ... . ... . .. . . .. . . .. . . ... . ... . ... . ... . .. . . .. . . .. . . ... . ... 10.21
REAR BRAKE SYSTEM BLEEDING . . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . ... . ... . ... . ... . .. 10.22
REAR BRAKE SYSTEM BLEEDING (INTERNATIONAL MODELS) . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . 10.23
DISTRIBUTION BLOCK BLEEDER SCREW (INTERNATIONAL MODELS) .. . ... . . .. . . .. . . .. . ... . ... 10.25
FRONT BRAKE MASTER CYLINDER .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . 10.26
REMOVAL. ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. . . ... . ... . ... . ... . ... . .. . . .. . . . 10.26
DISASSEMBLY.. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 10.26
INSTALLATION . . ... . ... . ... . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 10.26
BRAKE SWITCH REPLACEMENT . . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . 10.27
REAR BRAKE MASTER CYLINDER (DOMESTIC MODELS) .. . . .. . ... . ... . ... . ... . ... . ... . ... . ... 10.28
REAR BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... 10.28
BRAKE PEDAL REMOVAL / INSTALLATION . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 10.28
BRAKE SWITCH REPLACEMENT . . . .. . . .. . . .. . . .. . ... . ... . ... . . .. . . .. . . .. . ... . ... . ... . ... . . .. . . .. . 10.29
REAR BRAKE MASTER CYLINDER (INTERNATIONAL MODELS) . ... . ... . ... . .. . . .. . . .. . . .. . . ... 10.30
REAR BRAKE MASTER CYLINDER REMOVAL / INSTALLATION . .. . ... . . .. . . .. . . .. . . .. . . .. . ... . ... 10.30
BRAKE PEDAL REMOVAL / INSTALLATION . ... . ... . .. . . .. . . .. . . .. . . .. . . ... . ... . .. . . .. . . .. . . .. . . .. . 10.30
BRAKE PRESSURE SWITCH REPLACEMENT . . ... . .. . . .. . . .. . . .. . . .. . . .. . . ... . .. . . .. . . .. . . .. . . .. . 10.30
BRAKE PADS... . ... . ... . ... . ... . . .. . . .. . ... . ... . ... . ... . ... . . .. . ... . ... . ... . ... . ... . ... . ... . ... . ... . .. 10.32