2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 302Get this manual
BRAKES 12Install diaphragm, sight glass, cap and screwsMaster Cylinder Cap 15Field 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 1 2", (1.3 cm) from handlebar16Check brake system for fluid leaks and inspect all hoses and lines for wear or abrasionReplace hose if wear or abrasion is found
Sight Glass
FRONT MASTER CYLINDER
Cap Screws
Removal
1Clean master cylinder and reservoir assemblyMake sure you have clean work area to disassemble brake componentsRemove master cylinder from handlebars
Diaphragm 13Wiggle and press down on the cap to be sure it fits evenly and snug2
CAUTION