10
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
10.21
BRAKE FLUID BLEEDING
FRONT BRAKE SYSTEM BLEEDING
NOTICE
When bleeding the brakes, always start with the
furthest caliper from the master cylinder. This
procedure should be used to bleed brakes during
regular maintenance.
CAUTION
Always wear safety glasses when handling chemicals
and fluids.
IMPORTANT
Brake fluid will damage finished surfaces. Do NOT allow
brake fluid to come in contact with finished surfaces.
1. Clean the reservoir cover thoroughly before removal.
2. Remove the reservoir cover screws
q
, cover
w
, and
diaphragm from the front brake master cylinder.
3. Verify fluid is at specified level. If fluid level is low, add
brake fluid to .25” - .30” (6 - 8 mm) from the top of the
reservoir.
Polaris DOT 4 Brake Fluid
2872189
4. Loosely install the brake fluid reservoir diaphragm,
cover, and screws back onto the front brake master
cylinder to prevent spills. Do NOT tighten screws.
5. Remove old brake fluid from the reservoir with a Mity
Vac Pressure Test Tool (PN 2870975) and proceed to
step 12, or, continue with the following steps to bleed
the system manually.
6. Install a box end wrench on the front caliper bleeder
screw. Attach a clean, clear hose to fitting and place
the other end in a container. Be sure the hose fits
tightly on fitting.
7. Slowly pump the hand brake lever until pressure
builds and holds.
8. While maintaining lever pressure, open the bleeder
screw.
9. Close bleeder screw and release hand brake lever.
IMPORTANT
Do NOT release lever before bleeder screw is tight or
air may be drawn into the caliper.
10.Repeat procedure until clean fluid appears in bleeder
hose and all air has been purged. Add fluid as
necessary to maintain level in reservoir.
NOTICE
Maintain at least 1/2” (1.27 cm) of brake fluid in the
reservoir to prevent air from entering the master
cylinder.
11. Tighten bleeder screw securely and remove bleeder
hose. Torque bleeder screw to specification.
TORQUE
Bleeder Screw
46 in-lbs (5 N·m)
12.Repeat procedure on the remaining front caliper.
13.Add brake fluid to .25” - .30” (6 - 8 mm) from the top of
the reservoir.
Polaris DOT 4 Brake Fluid
2872189
BRAKE SYSTEM
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