How to Bleed and Replace Brake Fluid on a 2016 Polaris Sportsman 850 HIGH LIFTER

Shop parts for a 2016 Polaris SPORTS850HL ATV.

Overview

This proprietary MotoSport guide covers a complete brake fluid replacement and bleed procedure for the 2016 Polaris Sportsman 850 High Lifter (SPORTS850HL). Follow this guide exactly, use DOT 4 brake fluid only (do not use DOT 5 silicone), and dispose of old fluid per local regulations. Work on a cool machine, outdoors or in a well-ventilated area, and protect painted surfaces from spilled fluid.

Tools & Supplies

  • DOT 4 brake fluid (new, unopened)
  • Clear plastic hose that fits snugly over each bleeder nipple
  • Small catch bottle with some fresh fluid to avoid sucking air back
  • Line wrench or open wrench set (8mm, 10mm typical for Polaris bleeders)
  • Turkey baster or syringe to remove old fluid from the reservoir
  • Clean rags, gloves, eye protection
  • Jack/stands or ramps to access calipers if needed
  • Brake cleaner and rags for cleanup

Model Notes for the 2016 Sportsman 850 HIGH LIFTER

  • The High Lifter trim raises ride height and adds snorkels & intake mods. Those changes can expose lines differently than stock; inspect extended lines and clamps for chafing after lift kit installation.
  • This model generally uses conventional hydraulic front and rear brake systems (hand lever for front, foot pedal for rear). It is not equipped with factory ABS; bleeding follows standard hydraulic procedures.
  • Because High Lifter riders often run in deep water and mud, inspect caliper seals, banjo bolts, and hose routing for water ingress or abrasion. Replace any hose showing swelling, cracks, or soft spots before bleeding.
  • Polaris brake reservoirs are plastic; avoid letting DOT fluid contact paint and plastics for extended periods. Cap threads are plasticdo not overtighten.

Preparation

  • Park on level ground. Secure the machine in gear or with parking brake and disconnect battery ground if you prefer an extra safety step.
  • Clean around the reservoir cap(s) before opening to prevent contamination.
  • Remove the master cylinder cap and diaphragm. Use a turkey baster to remove most old fluid from the reservoir, leaving a small amount to keep the seal wet.
  • Top up with fresh DOT 4 fluid so the reservoir is near the fill line. Keep the cap off but covered loosely to avoid dust.

Bleed Order & Strategy

General hydraulic rule: bleed the caliper furthest from the master cylinder first, then proceed to the next furthest, finishing nearest. For the Sportsman 850 HIGH LIFTER this generally means:

  • 1) Rear caliper (if the rear master is separate, start from the rear caliper furthest from the rear master)
  • 2) Front calipers: start with the caliper furthest from the front master and finish with the caliper nearest the master cylinder

If you have separate front & rear master cylinders, treat each system independently using the same far-to-near rule.

Step-by-Step Bleeding Procedure

  1. Mount the machine so you can access the bleeder nipples. Remove wheel or guards if necessary for access.
  2. Attach the clear hose to the bleeder nipple and route the hose end into the catch bottle partially filled with fresh DOT 4 fluid to maintain a fluid seal and prevent air ingestion.
  3. Have an assistant slowly squeeze the brake lever (or press the pedal) to build pressure and hold it. Using the line wrench, open the bleeder nipple about a 1/4 to 1/2 turn so fluid flows and bubbles exit through the clear hose. Close the nipple before the assistant releases pressure. Repeat until you see clear fluid with no air bubbles.
  4. After each cycle, top up the master cylinder reservoir to prevent it running dry. Allow a few seconds for new fluid to settle so trapped air can migrate to the reservoir.
  5. Work systematically through each caliper in the order described. For dual-piston calipers, bleed until flow is clean and bubble-free from each nipple.
  6. When finishing each caliper, tighten the bleeder nipple to manufacturer snugnessdo not overtighten and strip the nipple threads. Wipe all exposed areas clean and remove any spilled fluid immediately.
  7. After all calipers on a system are bled, pump the brake lever/pedal several times to confirm a firm feel. If sponginess remains, repeat the bleeding process focusing on the caliper(s) most remote to the master cylinder.
  8. Once both systems (if separate) feel firm and bubble-free, top the reservoir to the correct level, reinstall the diaphragm & cap, and torque to recommended spec if available. Reconnect battery ground if you removed it.

Final Checks & Aftercare

  • Test the brakes at low speed in a safe area before returning to normal riding.
  • Inspect for leaks at bleeder nipples, banjo bolts, and hose fittings after the test ride. Retighten as necessary to specification.
  • Record the service date and mileage. For off-road / wet use like that common with High Lifter owners, inspect and consider fluid replacement annually or every 12 months; under extreme use, inspect more often.
  • Keep extra DOT 4 on hand and never mix DOT 4 with DOT 5 silicone. DOT 3 and DOT 4 can be mixed but DOT 4 is recommended for higher boiling point.

Common Troubleshooting

  • If you cannot get a firm pedal/lever: re-check for leaks, ensure the reservoir never ran dry during bleeding, and re-bleed starting at the furthest caliper. Replace caliper seals or master cylinder if internal leakage or worn components are suspected.
  • If air repeatedly returns to the reservoir: inspect hose fittings, master cylinder cap seal, and check for cracked reservoir or loose line connections allowing air entry.
  • If a caliper shows uneven pad wear or sticking after bleeding: clean caliper slides, inspect piston movement, and rebuild or replace the caliper if sticky.

Safety Reminders

  • DOT fluid is corrosive to paint and many plastics; clean spills immediately.
  • Never reuse old or contaminated fluid; always use fresh, sealed DOT 4 from a new container.
  • Wear eye protection and gloves. Keep fluid away from children & pets.

MotoSport Pro Tip

If you've added lift or extended hoses for the High Lifter conversion, consider replacing original hoses with braided stainless or high-quality OEM-style hoses rated for ATV use; they resist expansion and make bleeding more predictable, improving pedal/lever feel and longevity in deep-water applications.

Related Shopping Categories

Shop Brake Fluid for a 2016 Polaris SPORTS850HL ATV.

Shop Brake Bleeders for a 2016 Polaris SPORTS850HL ATV.

Shop Brake Pads for a 2016 Polaris SPORTS850HL ATV.

Shop Brake Lines for a 2016 Polaris SPORTS850HL ATV.

Shop Brake Tools for a 2016 Polaris SPORTS850HL 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.