2004 Polaris Touring Service Manual, Page 251Get this manual
BRAKESFINAL DRIVE Brake BleedingFluid Change
This procedure should be used to change fluid or bleed brakes during regular maintenance, or after complete brake serviceBrake fluid may damage painted or plastic surfacesTake care not to spill, and wipe up any spills immediatelyCover parts to avoid damage1Clean reservoir cover thoroughly2Remove screws, cover, and diaphragm from reservoir3Inspect vent slots (A) in cover and remove any debris or blockage4If changing fluid, remove fluid from reservoir with Mity Vac (PN2870975) pump or similar toolNOTE: Do not remove brake lever when reservoir fluid level is low5Add Polaris DOT brake fluid to within 14-516 (.6-.8 cm) of reservoir top6Install wrench on caliper bleeder screw fittingAttach clean, clear hose to fitting and place the other end in clean containerBe sure the hose fits tightly on fittingNOTE: Fluid may be forced from compensation port (B) when brake lever is pumpedPlace diaphragm (C) in reservoir to prevent spillsDo not install cover7Slowly pump lever (D) until pressure builds and holds8While maintaining lever pressure, open bleeder screwClose bleeder screw and release brake leverDo not release lever before bleeder screw is tight or air may be drawn into caliper9Repeat procedure until clean fluid appears in bleeder hose and all air has been purgedAdd fluid as necessary to maintain level in reservoirCAUTION: Maintain at least 12 (1.27 cm) of brake fluid in the reservoir to prevent air from entering the master cylinder10Tighten bleeder screw securely and remove bleeder hose11Add brake fluid to the proper level12Install diaphragm, cover, and screwsTighten screws to specificationReservoir Cover Torque 15-18 inlbs(1.7-.2.1 Nm)