How to bleed and replace brake fluid on a 2013 Polaris Sportsman 800 EFI 4X4 ATV

How to Bleed & Replace Brake Fluid on a 2013 Polaris Sportsman 800 EFI 4X4

Shop parts for a 2013 Polaris Sportsman 800 EFI 4X4 ATV.

This MotoSport guide walks you through a safe, complete brake fluid change and bleeding procedure for the 2013 Polaris Sportsman 800 EFI 4X4. Follow every step, use the right fluid, and respect safety precautions. This guide is written specifically for the Sportsman 800 model layout and components.

What you need

• DOT 4 brake fluid (Polaris recommends DOT 4; do not mix with DOT 5 silicone)
• Clear length of 1/8" or 3/16" tubing to fit bleeder nipples
• Brake bleeder wrench or appropriate open-end wrench
• Vacuum or pressure brake bleeder (optional but speeds the job)
• Clean catch container, funnel, turkey baster or syringe
• Clean rags, gloves, eye protection
• Jack, stands, or ramps to raise the unit safely (if needed)
• Service manual or torque wrench for any hardware re-tightening

Model notes & what to know about the 2013 Sportsman 800

• Reservoir location: master cylinder reservoir is on the right front handlebar area for the front brake and a separate reservoir/pedal master for the rear brakeverify which system you are working on; some configurations use an integrated master with separate circuits.
• Brake type: hydraulic disc brakes on both front and rear; no factory ABS on this model year.
• Bleed order: bleed the caliper farthest from the master cylinder first, working toward the closest. For the typical Sportsman layout that means rear caliper(s) first, then front caliper(s); if in doubt, visually trace the hydraulic lines from the master cylinder.
• Corrosion & rubber condition: inspect lines, banjo bolts, calipers, and dust boots while you work. Replace any cracked lines, leaking fittings, or torn bootsold fluid absorbs moisture and accelerates corrosion.
• Heat & contamination: never let dirt or water enter the reservoir. Brake fluid is hygroscopic and will contaminate quickly once opened.

Safety first

• Work on a level surface with the engine off and key removed.
• Secure the ATV so it can't roll or fall. Use chocks and stands as needed.
• Wear gloves and eye protection; brake fluid damages paint and skin.
• Properly dispose of used fluid at a local recycling center; do not pour down drains.

Step-by-step: Replace & bleed brake fluid

1. Preparation

• Clean the master cylinder reservoir cap and area to prevent contamination.
• Remove the reservoir cap and diaphragm; cover the opening with a clean rag to keep dirt out between steps.
• Check current fluid level and color. Dark or dirty fluid indicates replacement is due.
• If you plan a full system flush, remove as much old fluid from the reservoir as possible with a syringe or turkey baster.

2. Top up reservoir

• Pour fresh DOT 4 fluid into the reservoir to the recommended level (do not overfill). Keep the cap area clean.

3. Identify bleed order

• Locate all bleed nipples on calipers. Map the farthest caliper from the master cylinder and start there, progressing to the nearest.

4. Bleeding method A — Two-person manual

• Attach clear hose to the bleed nipple and place the other end in a catch bottle partially filled with fluid to prevent air backflow.
• Person A pumps the brake lever/pedal several times and holds pressure (or holds the lever/pedal down).
• Person B opens the bleed nipple about a quarter turn so fluid and air escape, then closes the nipple before Person A releases pressure. Repeat until clear, bubble-free fluid comes out.
• Keep the reservoir topped up during the entire process to avoid introducing air into the master cylinder.

5. Bleeding method B — Vacuum or pressure bleeder (recommended solo option)

• Connect the vacuum or attach the pressure reservoir to the master cylinder as per your tool instructions.
• Open each bleed nipple in sequence (farthest to nearest) while drawing fluid until clear, bubble-free fluid appears. Monitor and refill the master reservoir frequently.

6. Sequence and thoroughness

• Bleed until each caliper line produces clear fluid with no air. Continue cycling through calipers a second pass to ensure no trapped air remains.
• If using a dual-circuit master, bleed both circuits completely; on the Sportsman 800 you may have separate front/rear circuitstreat each independently.

7. Final checks

• With all bleeders closed and torqued to spec, refill reservoir to proper level and reinstall diaphragm & cap.
• Firmness test: with the ATV supported and wheels off the ground (if possible), apply brake lever/pedal repeatedly; brakes should feel firm and consistent. If spongy, repeat bleeding.
• Road test at low speed in a safe area to confirm braking performance before normal use.

Maintenance tips specific to the Sportsman 800

• Brake fluid interval: replace fluid every 1-2 years depending on use and moisture exposure. Aggressive riding or water crossing warrants more frequent changes.
• Inspect caliper slide pins, pads, and rotor condition while bleeding. Replace pads if worn unevenly; polish or replace rotors if deeply scored.
• Keep a small bottle of DOT 4 on hand for topping up during long rides.
• If you find persistent leaks at banjo fittings, replace crush washers and torque to spec rather than over-tightening.

Troubleshooting

• Persistent soft lever/pedal after thorough bleeding: check master cylinder seals and caliper pistons for leaks or collapse; rebuild or replace as necessary.
• Air return after bleeding: likely an open connection or a cracked hose. Inspect clamps, hoses, and bleed nipple threads for integrity.
• Contaminated reservoir cap or diaphragm: replace the cap assembly to prevent future ingress of moisture.

When in doubt, or if internal master cylinder or caliper service is required, consult a trained technician familiar with Polaris ATVs. Proper bleeding and fluid maintenance keep your Sportsman 800 stopping safely in all conditions.

Related Shopping Categories

Shop Brake Fluid for a 2013 Polaris Sportsman 800 EFI 4X4 ATV.

Shop Brake Bleeders for a 2013 Polaris Sportsman 800 EFI 4X4 ATV.

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Shop Brake Lines for a 2013 Polaris Sportsman 800 EFI 4X4 ATV.

Shop Brake Tools for a 2013 Polaris Sportsman 800 EFI 4X4 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.