How to Bleed & Replace Brake Fluid on a 2013 Polaris Sportsman BIG BOSS 800 6X6
Shop parts for a 2013 Polaris Sportsman BIG BOSS 800 6X6 ATV.
This MotoSport-exclusive procedure walks you step-by-step through draining, flushing, and bleeding the hydraulic brake system on a 2013 Polaris Sportsman BIG BOSS 800 6X6. This guide emphasizes safety, proven bleed technique, and model-specific checks to keep the 6x6 utility rig stopping reliably under heavy load.
Safety & prep
- Work on a level surface with engine off, parking brake engaged, and key removed.
- Wear eye protection and gloves. Brake fluid is corrosive to paint & plastics.
- Use DOT 4 brake fluid unless your owner's manual specifies otherwise.
- Have clean rags, a clear vinyl hose, a catch container, a wrench sized for bleed nipples, a turkey-baster or syringe, and fresh DOT 4 fluid. A hand or vacuum/pressure bleeder speeds the job but is optional.
- Keep new fluid sealed and avoid moisture contamination. Replace the reservoir cap immediately between steps to limit exposure to air.
What to know about the 2013 Sportsman BIG BOSS 800 6X6
- This is a heavy-duty utility ATV designed for towing and hauling, so brakes see higher duty cycles than a single-seat sport ATV. Expect more heat and possible accelerated fluid moisture absorption.
- There are multiple calipers and wheel locations to service on the 6X6 layout. Bleed every hydraulic circuit and inspect lines for chafing where racks, frames, or cargo tie-downs contact hoses.
- Master cylinder reservoir access may require removing or lifting the front cargo rack or small trim panels. Have basic hand tools ready and keep fasteners organized.
- Regular brake fluid service interval: for utility/working use, consider replacing fluid every 12-24 months. Heavy-duty or high-moisture environments warrant more frequent changes.
Step-by-step: drain, replace, & bleed
- Raise and support the machine so wheels are off the ground or have easy access to each bleed nipple. Chock wheels if not lifting the whole ATV.
- Clean the reservoir cap area thoroughly to prevent contamination. Remove cap and diaphragm; wipe out any surface grime.
- Use a turkey-baster or syringe to remove as much old fluid from the reservoir as possible. Do not mix old and new fluid.
- Top the reservoir with fresh DOT 4 until at the full mark. Keep the cap loose or placed nearby to monitor level while bleeding.
- Identify bleed nipples on each caliper. Fit a clear hose over the nipple and route into a catch bottle partially filled with clean fluid to prevent air reentry.
- Follow the correct bleeding sequence: always bleed the wheel farthest from the master cylinder first and finish with the closest. On a multi-axle 6x6 that means: start with the rear-most wheel that is farthest from the master cylinder, then the opposite rear, then the front wheels, finishing with the caliper closest to the master cylinder. If you are unsure which wheel is farthest, trace the brake lines from the master cylinder to determine distance.
- Manual pump method:
- Have an assistant slowly pump the brake lever or pedal several times and hold it down.
- Open the bleed nipple about a quarter turn to allow fluid and air to escape into the hose. When flow slows, close the nipple, then have the assistant release the lever/pedal.
- Repeat pump/open/close cycles until clear, bubble-free fluid flows and the lever/pedal feels firm.
- Vacuum/pressure bleeder method:
- If using a vacuum bleeder, attach to the bleed nipple and pull through until clear fluid appears; then close the nipple. If using a pressure bleeder on the reservoir, pressurize gently and open each nipple in sequence until clear fluid flows, closing each before moving to the next.
- Keep the reservoir topped to prevent air entering the system during the process. If the reservoir runs low, stop and refill before continuing.
- Repeat for every wheel/circuit following the farthest-to-closest order. After finishing, pump the brake lever/pedal to confirm firmness. If soft, repeat bleeding cycle.
- Torque-check caliper fasteners and re-seat any removed components. Wipe up spilled fluid and replace the reservoir diaphragm and cap securely.
- Lower the machine, perform a slow controlled road/test drive to confirm proper braking function and no leaks. Re-check fluid level after test ride and top if needed.
Inspection items & model-specific tips
- Inspect rubber hoses for cracking where they flex or pass under racks. Replace any hose that shows swelling, cracks, or abrasion.
- Check caliper pistons for uneven movement or corrosion; utility-use machines sometimes require caliper rebuilds from contamination or heavy duty cycles.
- Confirm parking/emergency brake cable routing and tension. Heavy loads on the 6X6 can expose stretched or frayed cables.
- After brake fluid change, monitor pedal feel over the next few rides as trapped air can migrate out over time and require a re-bleed.
- Keep an eye on master cylinder reservoir mounting and seals when removing racks for access &ndash they can be disturbed during cargo loading and maintenance.
Waste disposal
Collect old brake fluid and dispose of it at a hazardous waste facility or according to local regulations. Do not pour brake fluid down drains or on the ground.
When to call a pro
If you cannot obtain a firm brake pedal after repeated, correct bleeding; if you find collapsed or internally damaged hoses; if calipers bind or leak; or if you are uncomfortable accessing the master cylinder, have a certified ATV technician perform the service.
MotoSport provides parts and supplies for routine brake maintenance on the 2013 Polaris Sportsman BIG BOSS 800 6X6. Follow safe procedures, use fresh DOT 4 fluid, and inspect hydraulic components for wear to keep your utility rig stopping reliably.
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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.