How to Bleed and Replace Brake Fluid on a 2016 Polaris Sportsman 850 SP
Shop parts for a 2016 Polaris Sportsman 850 SP ATV.
This MotoSport.com proprietary guide walks you through safely flushing and bleeding the hydraulic brakes on a 2016 Polaris Sportsman 850 SP, including model-specific notes owners should know. Follow all safety steps, wear eye protection, and dispose of used fluid per local regulations.
What you need
- DOT 4 brake fluid (Polaris-specified or OEM equivalent)
- Clear tubing and a catch bottle
- Brake bleed kit or 12V vacuum pump (optional)
- Combination wrenches that fit the bleed nipples
- Turkey baster or fluid syringe (for master cylinder)
- Rags, shop towels, and brake-clean
- Service manual or phone to reference caliper locations
Important model notes for the 2016 Sportsman 850 SP
- The Sportsman 850 SP uses a hydraulic disc brake system that accepts DOT 4. Do not mix DOT 5 silicone fluid.
- Confirm whether your machine is equipped with Antilock / Traction Control or Electronic Power Steering; these systems do not require bleeding with the brakes but you should avoid contaminating electrical connectors when working around them.
- Park on level ground, block the wheels, and remove the key so the machine cannot be started while you work.
- If the system has been hot from prior use, allow it to cool before opening the master cylinder reservoir.
General procedure overview
The goal is to remove old fluid and air from the master cylinder and calipers leaving only clean DOT 4 in the system.
- Preparation: Clean the master cylinder reservoir cap area to prevent dirt entry. Remove the cap and diaphragm and use a turkey baster to remove roughly half the old fluid; this reduces contamination when you add fresh fluid.
- Top up the reservoir with fresh DOT 4. Keep the reservoir covered with the diaphragm or a light cap to reduce air ingress while you work.
- Identify bleed order: locate the brake master cylinder on your model and determine the caliper farthest from that master cylinder. Typical ATV bleed strategy – start with the caliper farthest from the master cylinder and proceed to the nearest. If unsure, identify master cylinder position and choose the caliper opposite and furthest for first bleed.
- Attach clear tubing to the bleed nipple and route to a catch bottle partially filled with a little fresh brake fluid to prevent air from being drawn back in.
- Crack the bleed nipple about a quarter turn. Have an assistant slowly pump the brake lever several times and then hold pressure. Open the nipple to let fluid and air escape until flow is clean, then close the nipple before the assistant releases pressure. Repeat until no air bubbles appear.
- Top up the master cylinder frequently during bleeding to avoid introducing air. Do not let the reservoir run dry at any time.
- Proceed to the next caliper following the distance-based order: farthest to nearest. Generally that means rear far side, rear near side, then front calipers, but always confirm by locating your master cylinder and choosing the farthest caliper first.
- After bleeding all calipers, check lever feel. It should be firm and consistent. If spongy, repeat the bleed sequence or use a pressure or vacuum bleeder for more thorough results.
- Once complete, tighten all bleed nipples to spec, clean spilled fluid, and refill the reservoir to the correct level. Reinstall reservoir cap and diaphragm securely.
- Test ride slowly in a safe area to confirm braking performance before returning to normal use.
Troubleshooting & tips
- Persistent sponginess: check for a soft brake line or damaged caliper seals. Replace damaged components and repeat bleeding.
- Contaminated fluid: if fluid appears dark or contains debris, perform a complete reservoir drain and full system flush, ensuring the master cylinder internal bore is cleaned as per service manual.
- ABS or sensors: if equipped with ABS, avoid pumping ABS components with a pressure bleeder unless the manual permits it. Always consult Polaris service info for ABS-specific procedures.
- Replacement parts: use OEM brake lines, caliper rebuild kits, or Polaris-approved components for best reliability.
Safety reminders
- Brake fluid will damage paint – wipe spills immediately and use brake-clean to remove residue.
- Never mix different types of brake fluid in the system. If DOT 3 is present and you want DOT 4, perform a full flush.
- If you are not confident doing the job, have a qualified technician at MotoSport service or another certified shop perform the bleed.
After bleeding, keep an eye on master cylinder level & brake performance for the next few rides. Regular brake fluid changes maintain stopping power and prolong system life on your Sportsman 850 SP.
Related Shopping Categories
Shop Brake Fluid for a 2016 Polaris Sportsman 850 SP ATV.
Shop Brake Bleeders for a 2016 Polaris Sportsman 850 SP ATV.
Shop Brake Pads for a 2016 Polaris Sportsman 850 SP ATV.
Shop Brake Lines for a 2016 Polaris Sportsman 850 SP ATV.
Shop Brake Tools for a 2016 Polaris Sportsman 850 SP 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.