1985-1995 Polaris ATV and Light Utility Hauler Service Manual, Page 139Get this manual
BRAKE SERVICE Type III Master Cylinder Overhaul Reassembly
1Always replace O-Ring seal, U-pack seal and cover gasket2Apply clean brake fluid onto piston, piston seals and cylinder boreInstall seals onto piston positioning U-pack lip (A) towards springSnap spring into place on pistonInstall piston assembly into special service tool PN 2870962 until U-pack seal is covered by tool as shownNOTE: This tool is used to guide the lip seal into the cylinder bore without damageInstall spring seat washer into boreInsert piston, still installed in tool, and seat in borePush piston through special toolRemove toolReinstall brake lever with bushing, bolt and nutIt is possible to bench bleed master cylinder before installing it on machineAttach short, flexible hose from outlet fitting back into reservoirFill reservoirSlowly squeeze and release lever until air bubbles no longer appear in reservoirReinstall master cylinder onto handlebar and reconnect brake lineAdjust master cylinder to level position centered on handlebarTorque clamp screws to 45-55 inIbsRe-bleed brake systemCheck fluid level in reservoirThe Type Master Cylinder should be 14"516" (.6.8 cm) below lip of reservoir openingField test machine before putting into serviceCheck for proper braking action and lever reserveWith lever firmly applied, lever reserve should be no less than 12" (1.3 cm) from handlebar