Polaris Outlaw 500, Service Manual

Page: 157 / 202

6.8
BRAKES
Brake Fluid Replacement and
Bleeding Procedure
NOTE: When bleeding the brakes or replacing the
fluid always start with the caliper farthest from the
master cylinder.
NOTE: This procedure should be used to change
fluid or bleed brakes during regular maintenance.
Front Brake Caliper Bleeding
1. Clean reservoir cover thoroughly.
2. Remove screws, cover, and diaphragm from master
cylinder reservoir.
3. Inspect vent slots in the cover and remove any debris or
blockage.
4. If changing fluid, remove old fluid from reservoir with a
Mity Vac™ (PN 2870975) or similar tool.
NOTE: Do not remove brake lever when reservoir
fluid level is low.
5. Add brake fluid to the upper level mark on reservoir.
6. Begin bleeding procedure with either front caliper. Install
a box end wrench on the 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.
NOTE: Fluid may be forced from compensation port
when brake lever is pumped. Place diaphragm in
reservoir to prevent spills. Do not install cover.
7. Slowly pump brake lever until pressure builds and holds.
8. While maintaining lever pressure, open bleeder screw.
Close bleeder screw and release brake lever.
NOTE: Do not release lever before bleeder screw is
tight or air may be drawn into caliper.
CAUTION
Always wear safety glasses during
these procedures.
CAUTION
Brake fluid will damage finished surfaces.
Do not allow brake fluid to come in contact
with finished surfaces.
Polaris DOT 3 or DOT 4 Brake Fluid
Bleeder Screw
RepairPro Service Manual