Bleeding the Hydraulic Brake System | Polaris 2002 guide

MAINTENANCE

General Maintenance

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause a springy or spongy brake lever action. Bleeding is necessary to remove air from the system.

CAUTION

Brake fluid will damage decals, paint, and some plastics. Wipe up spills immediately.

1Remove brake master cylinder reservoir cover and gasket.

2Fill the master cylinder reservoir to between the MIN and MAX marks or 1/4-5/16″(.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.

3Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container.

4Squeeze brake lever a full stroke. Then unscrew bleeder valve 3/4 of a turn to release air.

5Close bleeder valve and release brake lever.

6Repeat steps 4 and 5 until fluid flows from the bleeder valve in a solid stream free of air bubbles.

WARNING

Do not overfill the master cylinder. Fluid expansion may cause brakes to lock, resulting in serious injury or death.

7After bleeding is complete, refill the reservoir to the proper level. See Replenishing Brake Fluid on page 126.

8Reinstall the gasket and cover.

During the bleeding procedure, keep the brake handle in as level a position as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.

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Polaris 2002 manual Bleeding the Hydraulic Brake System

Contents

Page Proposition What’s the hottest thing on snow? Page Welcome Table of Contents HOW to USE this Manual Important Notes For Owners And Drivers Preservation Of The Environment Noise LevelAir Pollution HOW to USE this Manual Vehicle Identification Numbers Page Safety Operator Safety Safety Stay Away From Moving Parts Be Prepared for the Unexpected Be Seated and in Position to Control the Vehicle Always Wear Clothing Designed for Snowmobiling Do Not Overload Cargo Carrier Know the Limitations of the Machine Your Skills as a Driver Disabled Operators Safety Operation on Hard-Packed Snow or Slippery Surfaces Ice and Snow Build-up Driving in Hilly Terrain Riding Downhill Do Not Operate Engine With Clutch Guard RemovedDo Not Operate Engine With Drive Belt Removed Do Not Service Clutches Yourself Cold Weather Drive-AwayMachine Maneuverability Powder Snow Operation Safety Responsible Driving Wind Chill Chart F Windchill/Temperature Charts Wind Chill Chart C Clutch Cover Warning Decal Safety Decals And LocationsAirbox Warning Decal Pressure Cap Warning Decal Cargo Carrier Warning Decal Track Warning Decal Passenger Warning Vehicle Capable of Excessive Reverse Speed Standard Reverse Warning Decal Operation Warning Decal Electronic Reverse Warning Decal Operation Warning Decal Text Before Starting Engine Features and Controls Location of Controls Features and Controls Features and Controls Features Features and Controls Features and Controls Page Perfect FIT Front Suspension Adjustments IFS Adjustment OptionsIndependent Front Suspension IFS Shock Absorber Components Adjusting Front ShockSpring Preload Changing Shock Valving Indy Select IFS Shock Suspension Performance Tips Rear Suspensions Perfect FIT Rear Spring Tension Perfect FIT Rear Torque Arm Adjustment SKS Models Rear Torsion Spring Adjustment Xtra-12 Indy Select Front Track Shock Adjustment Indy Select Rear Shock Position Sensitive Shock PPS Optional Coil SpringsSuspension Coupling Front To Rear Coupling and the Front Rear Scissor Stop Frss Rear Rear Scissor Stop Rrss Attributes Rear To Front Coupling and the Rear Rear Scissor Stop Rrss Weight Transfer During Acceleration Xtra-10 and Edge Rear Rear Scissor Stop RrssXtra-12 Rear Rear Scissor Stop Rrss Handlebar Adjustment Accessories Traction Products Perfect FIT Wear Strips Page Start the Engine and Check Check Before Starting Engine Check Throttle and Brake for Proper Operation Throttle Safety Switch Hydraulic Brakes Brake Lever TravelLever Feel Mechanical Brakes Park Brake Lever Lock Check for Proper Operation of Steering System Track InspectionCheck for Securely Latched Hood Check Surroundings to Verify Clear Operating Area Page Operation Starting a Cold Engine Manual Start Starting Your Engine Starting a Warm Engine Starting a Cold Engine Electric Start Engine Break-In Oil Injection System Variable Exhaust SystemLubrication Track Warm-Up Operation Fuel Premium Fuel Switch Fuel System Deicers Fuel Reserve Capacity Low Oil Indicator Light Low Oil Level Carburetion Engine Stop Switch Throttle Lever System What IT does Throttle Condition Stopping Starting Reverse Operation Mechanical Reverse Operation Electronic Forward Altitude Setting Towing Page Maintenance Polaris Recommended Maintenance Program Maintenance Chart Tighten idler adjusting bolt jam Mile 240 km Initial Maintenance Inspection Mile 1600 km Maintenance InspectionMile 3200 km Maintenance Inspection Additional Services Performed + + 102 LL L 104 105 Suspension Lubrication X-10, Edge Jackshaft Bearing Greasing Driveshaft Bearing GreasingCoupler Greasing WideTrak Choke and Cable Lubrication Throttle Cable Lubrication Chaincase Oil Level Gearcase Oil Level WideTrak Models Intake Filter Spark Plug Selection Under Hood Air Intake System Normal OverheatingWet Fouled Spark Plug Removal and Replacement Water Pump Belt Inspection Variable Exhaust System V.E.S Plug Cleaning Procedure Water/Sediment Trap Service Oil Filter Fuel Filter/Fuel Lines General Carburetor Information Carburetor Adjustments Engine Cooling Liquid Cooled Models Exhaust System Coolant High Temperature Indicator Light Coolant MixtureCoolant Level Recovery System Models Flushing the Cooling SystemBleeding the Cooling System Surge Tank Models Edge RMKs Drive Chain Tension Hydraulic Brake Inspection Excessive Lever Travel Brake Components Replenishing Brake Fluid Bleeding the Hydraulic Brake System Mechanical Brake Lever Travel Headlight Adjustment Installing the Bulb Removing Halogen Bulbs High/Low BeamRemoving Halogen Bulbs High Beam Installing the Side Bulbs Wrap Around Taillight Bulb ReplacementRemoving the Side Bulbs Electronic Reverse Belt Removal Standard Belt Removal Electronic Reverse Belt Installation Standard Belt Installation Clutch System Drive Belt Deflection Clutch Alignment and Offset Reverse Kit Maintenance Clutch Center DistanceTorque Stop Chain Tension Accessory Reverse KitOil Level Oil Change Tool Kit Tool Pouch ClipAlways keep the tool kit with the snowmobile Maintenance Items For Your ProtectionFall Tune-Up Track Tension Data Suspension Weight Measurement Track Tension If the track needs adjustment Track Alignment Track Lubrication Steering Inspection and Adjustment Ski Alignment 146 Skag Replacement Ski SkagsSkag Identification Hi-Fax Wear Controls and Linkage Cleaning and Preservation of Hood, Chassis, and Trim Bearings Clutch and Drive SystemEngine and Carburetor Protection Electrical Connections Battery Transporting the Snowmobile Track and Suspension Battery Fluid Battery Removal Battery Connections Battery Installation 156 Troubleshooting Problem Solution perform only one change at a time Suspension Troubleshooting 12, 133″ Edge Edge RMK Xtra Lite Belt Wear/Burn Causes Solutions 164 165 166 167 168 Warranty Administration Service And Warranty InformationObtaining Service and Warranty Assistance Polaris Anti-Theft System Limited Warranty 172 Engine Oil Coverage Conditions Coverage Exclusions Index 177 178