How to Bleed and Replace Brake Fluid on a 2007 Polaris Sawtooth
Shop parts for a 2007 Polaris Sawtooth ATV.
This MotoSport service guide walks you step-by-step through replacing and bleeding the brake fluid on a 2007 Polaris Sawtooth ATV. The Sawtooth uses a conventional hydraulic braking system with a handlebar-mounted master cylinder for the front brake and a rear master or integrated rear caliper feed depending on equipment. It does not use antilock (ABS) electronics on standard models, so procedure is straightforward but requires care to avoid contamination and air in the lines.
Tools & supplies
- DOT 3 or DOT 4 brake fluid (use fresh, unopened fluid; check your owner’s manual if unsure)
- Clean catch bottle & clear hose to fit bleeder nipples
- Wrenches to fit bleeder nipples (usually 8mm or 10mm)
- Turkey baster or syringe to remove old fluid from reservoir
- Brake cleaner and lint-free rags
- Disposable gloves and eye protection
- Jack or ramps to support the ATV safely if wheel access is needed
- Torque wrench (for any banjo or caliper bolt reassembly)
Safety & prep
- Work on a level surface, engine off, parking brake disengaged, and wheels chocked.
- Brake fluid damages paint – cover body panels with rags or plastic.
- Keep fluid containers sealed – brake fluid absorbs moisture rapidly.
- Dispose of old fluid per local hazardous-waste regulations.
Overview of the procedure
The job has two main parts: (1) remove old fluid from the master cylinder reservoir and refill with new, clean fluid; (2) bleed each caliper from the farthest wheel from the master cylinder to the nearest to expel air. On the Sawtooth the typical order is rear caliper first, then front calipers left/right as appropriate.
Step-by-step: replace fluid and bleed brakes
- Remove the reservoir cap(s) and diaphragm. Use a turkey baster to extract as much old fluid as possible from the reservoir. Wipe the reservoir clean with a lint-free rag. Do not let dirt fall into the reservoir.
- Top the reservoir with fresh DOT 3 or DOT 4 brake fluid. Keep the cap off but protected so dust doesn’t enter.
- Locate the caliper bleeder nipples. Fit a clear hose onto the nipple and route into a catch bottle partially filled with fresh fluid to prevent sucking air back in. Have an assistant operate the brake lever/pedal; if working alone, use a one-man vacuum or pressure bleeder.
- Start with the wheel farthest from the master cylinder (often the rear caliper on the Sawtooth). Loosen the bleeder nut about a quarter turn. Have the assistant steadily depress the brake lever/pedal until it reaches the floor, hold it, then tighten the bleeder. Release the lever slowly. Repeat until fluid runs clear with no bubbles. Keep the reservoir topped up between cycles to avoid introducing air.
- Move to the next-farthest caliper and repeat the bleeding cycles. On dual-front setups, bleed the passenger-side then driver-side front calipers as needed. Always maintain reservoir fluid level.
- After bleeding each caliper, torque the bleeder nipple/banjo bolts snug to the manufacturer’s specification. If you disturbed any banjo bolts or hose fittings, tighten to the specified torque; if you don’t have the spec, tighten carefully and check for leaks under pressure.
- When bleeding is complete, fill the reservoir to the proper level, reinstall the diaphragm and cap, and clean any spilled fluid from painted surfaces with brake cleaner immediately.
- Test lever/pedal firmness with the engine off first, then with the engine idling (if applicable) to confirm firm, consistent pressure. Perform a slow test ride in a safe area to confirm braking performance before normal riding.
Troubleshooting & tips
- Persistent soft lever/pedal after bleeding can indicate internal caliper seals or master cylinder wear. Inspect calipers for leaking seals and spongy return; rebuild or replace components as needed.
- If you see foamy or dark fluid coming out repeatedly, continue flushing until clean fluid flows. Moisture in the system reduces boiling point & performance; if fluid is very contaminated, consider a complete line flush and caliper inspection.
- A one-person vacuum/pressure bleeder speeds the job and reduces the chance of introducing air if you work solo.
- Replace rubber seals and the master cylinder diaphragm if they appear hardened or cracked; cheap parts can cause leaks and contamination.
MotorSport model notes for the 2007 Polaris Sawtooth
- The Sawtooth’s handlebar-mounted master cylinder means front-brake lines are relatively short but routed through tight bends under the chassis – inspect lines and banjo fittings for chafing or cracking when reassembling.
- Many Sawtooth models use banjo fittings at the caliper attachment points; when removing these clean the mating surfaces and replace crush washers if disturbed.
- Rear caliper access can be limited on some Sawtooth trims; raise and support the ATV safely to access the bleeder nipple without stretching lines.
- Because of possible aftermarket brake upgrades on used Sawtooths, verify line & fitting compatibility if replacing hoses or calipers – use DOT-rated hoses and correct banjo sizes.
- After service, check for any brake drag or overheating during the first few miles; new fluid and air-free lines can change pad engagement slightly, so recheck torque and hose routing after a short test run.
Final checks
- Ensure no leaks at calipers, hose fittings, or master cylinder.
- Confirm lever/pedal feel is firm and consistent.
- Properly dispose of old brake fluid and used rags.
If you need replacement hoses, caliper rebuild kits, seals, or fresh DOT-rated fluid for your Sawtooth, MotoSport carries the right parts and supplies to finish the job correctly.
Related Shopping Categories
Shop Brake Fluid for a 2007 Polaris Sawtooth ATV.
Shop Brake Bleeders for a 2007 Polaris Sawtooth ATV.
Shop Brake Pads for a 2007 Polaris Sawtooth ATV.
Shop Brake Lines for a 2007 Polaris Sawtooth ATV.
Shop Brake Tools for a 2007 Polaris Sawtooth ATV.
Disclaimer: This guide is provided for general informational purposes only and is not intended to replace your motorcycle's official owner's manual. Always refer to your manufacturer's documentation for model-specific instructions, torque specifications, safety procedures, and maintenance requirements. If you are unsure or inexperienced, consider seeking assistance from a qualified mechanic or technician.