2005 Polaris Sportsman 700/800 EFI Service Manual, Page 241Get this manual
BRAKES 13Install diaphragm, cover and screwsTighten screws to specification inlbs(0.56 Nm)2Place shop towel under brake line connection at master cylinderLoosen banjo bolt; remove bolt and sealing washersCAUTION: Brake fluid will damage finished surfacesDo not allow brake fluid to come in contact with finished surfaces3Remove master cylinder from handlebars4Hold brake upright and continue to remove master cylinderCover brake line to avoid spillage
MASTER CYLINDER INSTALLATION
Reservoir Cover Torque inlbs(.56 Nm) 14Field test machine at low speed 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 handlebar15Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasionReplace hose if wear or abrasion is foundNotice: When replacing the brake master cylinder assembly or master cylinder parts, use the correct partsThere are different brake master cylinders for the different Polaris ATV modelsRefer to your parts manual or guide for the correct partsThis master cylinder is not serviceable and is replaced as unit1Install master cylinder on handlebarsTorque mounting bolts to 25 inlbs(3 Nm)Torque the inside bolt first as indicated in the illustration to the right5 in.lbs(.56 Nm)