Snowmobile Polaris 550 Transport Trail Touring. Instruction - part 22

86

MAINTENANCE

Brakes

n

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See 

page 47.

Brake pads must be replaced when the brake pad material becomes thin-

ner than the backing plate (approximately 1/16I). A kit is available for 

replacing brake pads. See your dealer.

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance 

develops, bring the machine to an authorized Polaris dealer for inspec-

tion and adjustment.

Brake Components

1. Brake Caliper
2. Brake Disc
3. Brake Pad Material 

(Replace when thickness is 

less than 1/16I/1.5 mm).

WARNING

Brake failure during operation can result in serious injury or death. Properly 

functioning brakes are vital to your safety. Be sure the brake pads do not 

drag on the disc and that brake lever travel is not excessive.
Always replace brake pads when the brake pad material becomes thinner 

than the backing plate (approximately 1/16

I

).

2

1

3

87

MAINTENANCE

Brakes

Brake Fluid

On some models, the brake fluid level can be seen through a plastic 

sight glass in the brake reservoir. If the fluid is sufficient, the sight glass 

will be black. If the sight glass is any color other than black, add brake 

fluid.

On all other models, frequently check the reservoir to be sure it contains 

the correct amount of fluid. To add fluid, remove the master cylinder 

reservoir cover. Add the recommended brake fluid to bring the level up 

to the top of the fluid level mark on the inside of the reservoir.

Replace brake fluid at least every two years with Polaris DOT 4 high 

temperature brake fluid. See page 113 for the part numbers of Polaris 

products.

WARNING

After opening a bottle of brake fluid, always discard any unused portion. 

Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rap-

idly absorbs moisture from the air. The moisture causes the boiling tempera-

ture of the brake fluid to drop, which can lead to early brake fade and the 

possibility of accident or serious injury.

WARNING

Keep the master cylinder cover free of dirt and debris. The vent slits allow for 

diaphragm movement, and if they become plugged, movement of brake fluid 

below the diaphragm may be restricted, altering brake function.

CAUTION

Brake fluid will damage decals, paint and some plastics. Always wipe up 

spills immediately.

88

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action. 

Bleed the system before operating the snowmobile.

During the bleeding procedure, keep the brake handle as level as possi-

ble. The reservoir must be in this position to minimize the possibility of 

air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX 

marks or 1/4-5/16I (.6-.8 cm) below the lip of the reservoir open-

ing. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the 

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder 

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a 

solid stream free of air bubbles.

7. After bleeding is complete, refill the reservoir to the proper level. 

See page 87. 

8. Reinstall the gasket and cover.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of brakes, 

which could cause an accident and lead to serious injury or death. Never 

operate the vehicle with a spongy-feeling brake lever.

WARNING

Overfilling the master cylinder leaves no room for fluid expansion and may 

cause the brakes to lock, resulting in serious injury or death. Always add 

brake fluid to the fill line as recommended.

89

MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following pro-

cedure.

1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight 

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim. The most intense part of the headlight 

beam should be aimed 2I (5.1 cm) below the mark placed on the 

wall.

NOTE: Rider weight must be included on the seat.

5. Turn the adjustment nut (+), located inside the hood, just below the 

headlamp opening. Turn the knob in or out as needed for proper 

aim.

2

I

 (5.1 cm)

Lamp Center Height

25 ft. (7.6 m)

+