Polaris 400 H.O. Offroad Vehicle User Manual

Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self-
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
WARNING! An over-full master cylinder may cause brake drag or brake lock-
up, which could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an adequate
level. See page 28.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc. Clean any grease using a rec-
ommended brake cleaner or alcohol. Do
not use spray lubricants or other petroleum-based products. If you
discover any damage (cracks, excessive corrosion, warping) see
your dealer for service before operating.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 30.
3/64" (1 mm)