Snowmobile Arctic Cat (2002 year). Manual - part 124

8-54

AF293D

DISASSEMBLING

1. Remove the snap ring on the stationary side of the

caliper.

AF318A

2. Remove the brake pad support plate.

AF356

3. Remove the stationary brake pad.

AF354

4. Remove the movable brake pad.

5. Remove the brake piston.

AF353

6. Remove the brake actuator arm return spring.

AF351A

7. Loosen and remove the three cap screws securing

the brake cable bracket and remove the bracket.

8-55

8

AF326

8. Remove the brake actuator arm assembly from the

caliper.

AF283

9. Pull out on the quick-adjust knob and turn

counterclockwise to remove.

AF328

10. Remove the adjustment bolt and spring from the

quick-adjust knob.

AF333

11. On the rear of the caliper, loosen and remove the

jam nut, washer, spring, and ball assembly.

AF331

CLEANING AND INSPECTING

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

1. Using a calipers, measure the stationary and

movable brake pads. The movable brake pad

thickness must exceed 12.7 mm (0.500 in.). The

stationary brake pad thickness must exceed

6.22 mm (0.245 in.).

0730-504

„ NOTE: When replacing brake pads, always
replace both pads as a set.

2. Wash all brake components with parts-cleaning

solvent and dry thoroughly.

8-56

3. Inspect all brake components for signs of wear,

fatigue, cracks, or stripped threads.

4. Inspect the spring for cracks, stretching, or

unusual bends.

5. Inspect the brake cable for any signs of fraying or

broken strands. Replace as needed.

ASSEMBLING

1. In the rear mounting hole of the caliper,

temporarily install the mounting cap screw. In

sequence, install the alignment ball (apply a small

amount of grease to the ball), spring, washer, and

jam nut. Turn the jam nut in until slight spring

pressure is felt; then remove the mounting cap

screw.

AF331

2. Apply Arctic Cat Hi-Temp Wheel Bearing Grease

(p/n 0436-094) to the actuator shaft.

AF327

3. Insert the adjustment bolt with spring and quick-

adjust knob into the actuator assembly and turn in

2 or 3 turns.

AF329

4. With the actuator shaft arm in the 11 oclock

position (located over the front mounting hole),

install the actuator shaft into the brake caliper

assembly.

AF338

5. Place the brake cable bracket and rope guide into

position and secure with the three cap screws and

lock washers.

AF352A

6. Install the brake arm actuator return spring.

8-57

8

AF351A

7. Install the brake piston making sure that the slot in

the piston aligns with the roll pin in the caliper.

AF325A

8. Install the movable (thick) brake pad into the

caliper making sure that the slot in the pad aligns

with the roll pin in the caliper.

AF320

9. Install the snap ring into the caliper making sure

that the sharp edge of the snap ring faces out and

the opening faces down.

AF318A

10. Install the brake pad support plate with the large

tab located in the opening of the snap ring.

AF322

11. Install the stationary (thin) brake pad into the

caliper making sure the slot in the pad aligns with

the small tab on the support plate. Use a rubber

band to hold the pad and plate in position.

INSTALLING

1. With the rubber band holding the stationary pad

and support plate in position, install the caliper

assembly over the brake disc. Remove the rubber

band.

AF321A

! WARNING

Be sure the snap ring is fully seated. Personal
injury may result if the snap ring isnt seated prop-
erly within the slot of the caliper.

! CAUTION

Make sure that the brake pads are properly
positioned in the caliper or damage to the brake
system will result.