Snowmobile Arctic Cat (2002 year). Manual - part 123

8-50

AF205

INSPECTING

„ NOTE: Whenever a part is worn excessively,
cracked, or damaged in any way, replacement is
necessary.

1. Inspect the screw securing the brake lever for wear

and for cracked, stretched, or damaged threads.

2. Inspect the O-ring for deterioration and distortion.

AF206

3. Inspect the reservoir for cracks and leakage.

4. Inspect the brake fluid hose for cracks,

deterioration, and the condition of the fittings

(threaded and compression).

ASSEMBLING

0733-786

AF207

1. Apply approved high temperature brake fluid to

the O-ring seal; then install the seal on the

reservoir.

2. Install the reservoir on the master cylinder. Secure

with two screws.

AF205

KEY

1. Brake Assy
2. Brake Lever
3. Lever Mounting 

Screw

4. Lock Nut
5. Reservoir
6. Gasket
7. Cover
8. Screw

9. Machine Screw

10. O-Ring
11. Master Cylinder
12. Lock Washer
13. Screw
14. Clamp
15. Dimmer Control 

Assy

16. Dimmer Control 

Housing

17. Switch Assy
18. Dimmer Knob
19. Handwarmer 

Switch

20. Cover Plate
21. Self-Tapping 

Screw

22. Brakeline
23. Adapter Fitting

8-51

8

3. Install the brake lever. Secure with a screw and a

new lock nut. Tighten the lock nut just to the point

of ensuring free brake lever movement.

AF202

INSTALLING

1. Position the brake assembly on the handlebar.

Secure with two torx-head machine screws and

clamp; tighten securely.

2. Install the hose on the master cylinder. Tighten

securely.

AF911D

3. Slide the brakelight switch into the brake control

until the self-locking tab snaps into position.

Lightly pull on the switch to make sure it is

properly secured.

4. Bleed the brake system.

Brake System 

(120 cc)

REMOVING AND INSPECTING

736-148B

1. Remove the forward drive chain guard.

„ NOTE: It will be necessary to support the hood
once the hood cable is removed.

2. Loosen the Allen-head retaining pin securing the

brake cable to the brake band.

3. Loosen the jam nut securing the threaded portion

of the brake cable to the brake bracket; then

remove the brake cable from the bracket and brake

band. Account for a spring.

4. Remove the snap ring securing the brake band to

the mounting bracket; then remove the brake band

from the engine compartment.

A003

5. Remove the C-clip securing the brake lever pin in

the brake housing; then remove the pin and lever.

! WARNING

Do not over-tighten the lock nut. Over-tightening
the lock nut will cause the brake lever to bind. The
lever must work freely and fully return to its stop
after installation.

! WARNING

A new lock nut must be used to secure the brake
lever.

KEY

1. Lock Nut
2. Bushing
3. Rivet
4. Chain Ten-

sioner

5. Spring
6. Tab

7. Roller
8. Washer
9. Cap Screw

10. Bracket
11. Cap Screw
12. Spacer
13. Clutch

14. Brake Band
15. Retaining Pin
16. Washer
17. Snap Ring
18. Spacer
19. Washer
20. Lock Washer

8-52

A998

6. Disconnect the brake cable from the lever; then

slide the brake cable out of the lever.

A999

7. Remove the handlebar pad and cut the cable tie

securing the brake cable to the steering post.

„ NOTE: Note the location of the cable tie for
assembly.

8. Inspect the brake band and brake cable for wear.

„ NOTE: The brake band pad material thickness
must be at least 1.6 mm (1/16 in.) or replacement is
necessary.

9. Inspect the brake cable for damage or fraying.

INSTALLING

1. Route the cable through the slot in the brake

housing and insert the cable end into the housing.

2. Seat the cable drum into the brake lever recess;

then secure the brake lever with a pin and C-clip.

A999

A998

3. Place the brake band into position on the bracket

and secure with a washer and snap ring.

A003

4. Slide the spring onto the brake cable; then insert

the cable end into the brake band. Tighten

securely.

A004

8-53

8

5. Secure the threaded portion of the brake cable to

the bracket with the jam nuts.

A005

6. Secure the brake cable to the steering post with a

cable tie; then install the handlebar pad.

CHECKING BRAKE LEVER TRAVEL

1. Compress the brake lever fully.

2. Check the distance between the brake lever and

the lever stop. The distance must be within a range

of 6-13 mm (1/4-1/2 in.).

0725-565

3. If travel distance is not as specified, adjust the

brake lever travel.

ADJUSTING BRAKE LEVER TRAVEL

0735-457

„ NOTE: The brake band should lock tightly when
the brake lever is compressed and should disen-
gage when the lever is released. If adjustment is
necessary, use the following steps.

1. Loosen the rearward jam nut on the brake cable.

2. Tighten the forward jam nut to set up the brake.

3. Check the brake lever travel distance periodically

while tightening the forward jam nut. When the

distance is within the specified range of 6-13 mm

(1/4-1/2 in.), tighten the rearward jam nut to

secure the adjustment.

Brake System

(Mechanical/Quick-Adjust)

REMOVING

1. Remove the cotter pin, washer, pin, and clevis

from the brake actuator arm.

AF297D

2. Remove the recoil starter rope from the brake

cable bracket.

3. Loosen the jam nut on the brake cable and remove

the cable from the bracket.

4. Loosen and remove the two mounting cap screws

(account for the front alignment ball) and remove

the brake caliper.

AF460D