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Old 02-17-2013, 03:38 PM
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Bleeding Brakes

Having a problem bleeding the front and mid brakes on my 93 Big boss 6X6. I have cleaned all the lines, replaced the pads and installed a NEW master cylinder. I have tried the traditional method of pumping the master and bleeding each caliper, used a mity vac and also dropped a line into a bottle of brake fluid while using the traditional method, but still cannot get any pressure. I have the machine on blocks so I can rotate the tires.While turning the front tires I can apply the brake, but it goes all the way to the handlebar, but the brakes do stop the tires. I just cannot figure out why I don't have more brake pressure on the Master Cylinder. The right side,Rear brake works fine. Any thoughts and/or advise would be greatly appreciated. I'm lost on this one. I have been reading here and other places that bleeding the brakes on these machines can really be a problem
Thanks in advance.
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Old 02-17-2013, 09:16 PM
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Welcome to the board!
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Old 02-18-2013, 07:15 PM
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I have the same problem help
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Old 02-18-2013, 07:21 PM
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I've had to reverse bleed sometimes if its air-locked. I've not had to do that to any Polaris units, but vehicles and other brands of atvs.
"Big Bad Wolf" 2004 Sportsman 700 EFI, Mine
"Lil' Red" 1999 Sportsman 335, The Wife's Ride
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Old 02-23-2013, 04:57 AM
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Try leaving lid off of master cylider while you bleed.
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Old 02-23-2013, 08:54 AM
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On my '01 sportsman, there's an adjustment at the calipers to compensate for pad wear/caliper travel. Your caliper may be running out of travel.

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'01 Polaris Sportsman 500 HO project (needs a 'lil TLC. OK, OK, a LOT of TLC)
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My other ride is a 2-stroke sport quad.
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Old 09-13-2014, 12:44 AM
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I hate to wake a sleeping bear but I have a '89 Big Boss 4x6 and I have the exact same issue. I got it used very cheap and has only 50 miles on it (was at a state park for 25yrs and was never used...). I had to blow crud out of all of the lines as they were clogged. Had to buy two new master cylinders (each handle) as they were both destroyed beyond economical repair. New pair of CHICOM MC's cost me $70 from eBay. Right side (rear) works excellent and has good pressure. The left side (fronts and gearbox brake) are very very weak with the handle pulled all the way back. With it up on a jack you can spin the front tires and squeezing the brake handle it will stop but I can still turn the tires with my hands. The gearbox caliper/brake isn't strong enough to stop the force of the new belt with the weak pressure. I have tried a MityVac to suck new fluid in. I have even replace the left MC with a different brand new unit. I even installed the old unit that I rigged back up -- no matter what, it has very weak hydraulic pressure. Air in the four-way manifold? Any good tricks? I though I read here that I should unhook the calipers and squeeze the pistons out farther, compress them then re-install and then test the brakes.
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