How to Bleed and Replace Brake Fluid on a 2016 Polaris Sportsman Touring 850 SP

Shop parts for a 2016 Polaris Sportsman Touring 850 SP ATV.

This MotoSport.com guide walks you through safely draining, flushing, and refilling the hydraulic brakes on a 2016 Polaris Sportsman Touring 850 SP. Follow each step carefully, use the correct DOT brake fluid, and observe all safety precautions. If you’re unsure about any step, contact a professional mechanic.

What you need

  • DOT 4 brake fluid (Polaris recommends DOT 4 for this model)
  • Clear plastic tubing that fits the bleed nipples
  • Catch bottle for old fluid
  • Brake bleeder wrench or appropriate open-end wrench
  • Turkey baster or fluid syringe
  • Clean rags and brake cleaner
  • Floor jack or ramps and jack stands (for wheel access)
  • Latex or nitrile gloves and eye protection
  • Assistant (recommended for manual bleeding)

Model-specific notes for the 2016 Sportsman Touring 850 SP

  • The Touring 850 SP uses hydraulic disc brakes front and rear with a combined braking system; bleeding both circuits is necessary to restore full pedal/lever feel.
  • Master cylinder reservoirs are plastic and sit on the handlebar for the front and on the rear carrier for the rear/combined circuit – inspect reservoir boots for deterioration before opening.
  • Polaris brake lines on this model can have brackets that trap air during bleeding; ensure lines are routed naturally and gently cycle the handlebars/wheels to move trapped air.
  • ABS is not present on this model, so standard manual or pressure bleeding methods apply without needing ABS-specific tools.
  • If the bike has aftermarket calipers or braided lines, verify compatible fluid type and torque specs for bleed screws; aftermarket components may alter bleeding order or procedure.

Safety first

  • Work on a level surface with the engine off and ignition key removed.
  • Keep brake fluid off painted surfaces – it damages plastic and paint. Wipe spills immediately and use brake cleaner if needed.
  • Use fresh, sealed DOT 4 fluid. Do not mix DOT 3 and DOT 4 indiscriminately; follow Polaris recommendations.

Overview of the procedure

Bleed and replace brake fluid in this order: rear circuit first, then front circuit. This reduces cross-contamination in the combined system and helps purge air toward the master cylinder then out of the system.

Step-by-step: Drain old fluid from reservoirs

  1. Remove the seats and panels as needed to access both master cylinder reservoirs. Clean the caps and area to prevent contamination.
  2. Use a turkey baster or syringe to remove as much old fluid from each reservoir as possible. Dispose of fluid properly.
  3. Top reservoirs with fresh DOT 4 fluid to the max mark. Keep the caps loosely reinstalled to limit contamination while allowing pressure equalization.

Step-by-step: Manual two-person bleeding (recommended)

  1. Position the ATV so you can access the bleeder screw on the caliper you’re working on. A front wheel lift or rear support may be necessary for wheel rotation.
  2. Attach clear tubing to the caliper bleed nipple and submerge the other end in a bottle partially filled with fresh fluid to prevent air re-entry.
  3. Have your assistant sit on the ATV and apply steady pressure to the brake pedal or front lever (hold it down) while you open the bleed screw about a quarter turn to let fluid and air escape.
  4. Close the bleed screw before the assistant releases the pedal/lever. Repeat this press-open-close cycle until no bubbles appear in the tubing and the fluid runs clear.
  5. Keep the reservoir topped between cycles to avoid introducing new air. Periodically clean the reservoir cap area to prevent contamination.
  6. Torque bleed screws to Polaris spec (check owner service manual for torque values) and wipe down components.
  7. Repeat for each caliper in the recommended order: rear calipers first (right then left), then front calipers (right then left). If the Sportsman Touring has a linked rear/front circuit configuration, bleed the rear combined circuit completely before the front circuit.

Step-by-step: Vacuum or pressure bleeding (single-person option)

  1. Use a vacuum pump on the bleed nipple and operate until clear, bubble-free fluid appears. Keep the reservoir topped.
  2. Alternatively, use a low-pressure pressure bleeder on the reservoir per the tool manufacturer’s instruction — keep pressure modest to avoid forcing contaminants or collapsing reservoir seals.
  3. Follow the same caliper order as manual bleeding and confirm no air remains by checking lever/pedal firmness.

Flush entire system and replace fluid

  1. Continue bleeding each caliper until the reservoir fluid is clear and new. Replace reservoir fluid with fresh DOT 4 during the process so the system is fully refreshed.
  2. When bleeding is complete, ensure all bleed screws are tightened to spec. Clean overflow and cap areas, then reinstall reservoir caps and any removed panels.
  3. Operate brakes several times at low speed in a safe area to bed the pads and verify firm pedal/lever feel before riding aggressively.

Inspection & maintenance tips specific to the 2016 Sportsman Touring 850 SP

  • Inspect caliper pistons for corrosion and boots for tears. Replace seals or calipers if pistons stick or boots are compromised.
  • Check rotor condition for grooves, warpage, or thickness; replace rotors that are below Polaris minimum thickness or visibly damaged.
  • Inspect flexible lines for swelling, cracking, or damage. Replace aged rubber lines with OE or braided stainless lines rated for DOT 4.
  • Confirm master cylinder reservoir caps and diaphragms seal properly – a leaking cap can allow moisture ingress, reducing fluid life.
  • Keep a service interval: brake fluid absorbs moisture over time. Replace fluid every 1-2 years or per Polaris maintenance recommendations, and sooner if the fluid appears dark or contaminated.

Troubleshooting

  • Spongy lever/pedal after bleeding: recheck for air in the system, inspect hose routing for high points that trap air, and repeat bleeding with the wheel rotated to help dislodge pockets.
  • Brake drag after bleeding: ensure bleed screw is fully tightened, caliper slide pins are lubricated and free, and pistons are retracting fully.
  • Continuous fluid loss: inspect for leaks at bleed screws, calipers, hoses, and master cylinder; replace any leaking components.

Final checks

  • Verify fluid level sits between min & max lines with caps torqued per spec.
  • Confirm no leaks after a short test ride and that brakes feel firm and consistent.
  • Record the service date and miles/hours for future maintenance tracking.

Performing a full brake fluid flush and bleed on your 2016 Polaris Sportsman Touring 850 SP restores stopping performance and extends component life — and following model-specific items above ensures a complete, MotoSport-approved job.

Related Shopping Categories

Shop Brake Fluid for a 2016 Polaris Sportsman Touring 850 SP ATV.

Shop Brake Bleeders for a 2016 Polaris Sportsman Touring 850 SP ATV.

Shop Brake Pads for a 2016 Polaris Sportsman Touring 850 SP ATV.

Shop Brake Lines for a 2016 Polaris Sportsman Touring 850 SP ATV.

Shop Brake Tools for a 2016 Polaris Sportsman Touring 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.